Robotic vacuum cleaner and docking station for a robotic vacuum cleaner

ABSTRACT

A robotic vacuum cleaner docking station has a mechanical transfer mechanism that is used to transfer dirt from a robotic vacuum cleaner to a docking station.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Patent Application No.63/013,781, filed on Apr. 22, 2020, the entirety of which isincorporated herein by reference.

FIELD

This disclosure relates generally to robotic surface cleaning apparatusand docking stations that receive dirt collected by a robotic surfacecleaning apparatus.

INTRODUCTION

Various types of robotic or autonomous surface cleaning apparatus areknown. A robotic vacuum cleaner may have a docking station that chargesthe robotic vacuum cleaner when the robotic vacuum cleaner is connectedor docked to the docking station. Also, a docking station may have asuction motor to draw dirt from a dirt storage chamber in a roboticvacuum cleaner and an air treatment member to remove entrained dirt fromthe air drawn into the docking station for the dirt storage chamber of arobotic vacuum cleaner.

SUMMARY

This summary is intended to introduce the reader to the more detaileddescription that follows and not to limit or define any claimed or asyet unclaimed invention. One or more inventions may reside in anycombination or sub-combination of the elements or process stepsdisclosed in any part of this document including its claims and figures.

In one aspect of this disclosure, which may be used by itself or withone or more of the other aspects disclosed herein, an autonomous surfacecleaning apparatus may have a mechanical transfer member, which may beprovided inside of the automated surface cleaning apparatus (which mayalso be referred to as a robotic surface cleaning apparatus, roboticvacuum cleaner, robot vac or the like), which is used to convey dirtthat has been collected in the robotic surface cleaning apparatus to adocking station. The mechanical transfer member may comprise, forexample, a ram for conveying dirt from an air treatment unit of therobotic surface cleaning apparatus into the docking station. Themechanical transfer member may be configurable between a floor cleaningposition and one or more dirt emptying positions. In the floor cleaningposition, the mechanical transfer member may be positioned at a firstside and/or external to an air treatment unit of the robotic surfacecleaning apparatus. As the mechanical transfer member is moved to thedirt emptying position, the mechanical transfer member may be moveablethrough at least a portion of the air treatment unit of the roboticsurface cleaning apparatus such that dirt collected inside the airtreatment unit is moved by the mechanical transfer member through atleast a portion of the air treatment unit and towards the dockingstation. Optionally, the mechanical transfer member may move dirt out ofa dirt outlet of the air treatment unit and/or into the docking station.An advantage of such a design is that the docking station need not havea suction motor or an air treatment member to filter dirt from the airdrawn into the robotic docking station. It will be appreciated that sucha mechanical transfer member may be used by itself (e.g., it may be thesole dirt transfer mechanism) or it may be used with any other mechanismdisclosed herein or in use in the robotic docking station arts. Forexample, it may be used with a docking station that incorporates asuction fan to draw air through a dirt chamber of a robotic surfacecleaning apparatus.

In accordance with this broad aspect, there is provided an autonomoussurface cleaning apparatus comprising:

-   -   (a) a primary air flow path extending from a dirty air inlet to        a clean air outlet:    -   (b) a primary suction motor positioned in the primary air flow        path;    -   (c) an air treatment unit positioned in the primary air flow        path wherein, when the autonomous surface cleaning apparatus is        positioned on a floor, the air treatment unit has an upper side,        a lower side, a first end having a first side positioned between        the upper and lower sides and a second end having a second side        positioned between the upper and lower sides, the second side is        spaced apart from the first side in a first direction; and,    -   (d) a mechanical transfer member moveable in the first direction        through at least a portion of the air treatment unit whereby        dirt collected in the air treatment unit is moved in the first        direction through the air treatment unit.

In some embodiment, the first direction may be generally horizontal.

In some embodiments, a dirt outlet may be provided at the second end.

In some embodiments, the mechanical transfer member may be moveable inthe first direction from the first side to the second side.

In some embodiments, the autonomous surface cleaning apparatus may havea dirt outlet which communicates with a docking station when theautonomous surface cleaning apparatus is docked at the docking stationand the autonomous surface cleaning apparatus is operable in a floorcleaning mode and a dirt emptying mode, in the floor cleaning mode themechanical transfer member may be positioned at the first side and inthe dirt emptying mode the mechanical transfer member may be moveable inthe first direction from the first side to the second side and throughthe dirt outlet.

In some embodiments, the first side may have a mechanical transfermember inlet port and, in the floor cleaning mode, the mechanicaltransfer member may be positioned exterior to the air treatment unit.

In some embodiments, the mechanical transfer member may comprise asweeping portion and a drive portion and, in the floor cleaning mode,the sweeping portion may be positioned interior to the air treatmentunit and the drive portion may be positioned exterior to the airtreatment unit.

In some embodiments, the air treatment unit may comprise an airtreatment member and a dirt collection chamber external to the airtreatment member and the mechanical transfer member may be moveable inthe first direction through at least a portion of the dirt collectionchamber.

In some embodiments, the air treatment unit may comprise an airtreatment member having a dirt collection region internal of the airtreatment member and the mechanical transfer member may be moveable inthe first direction through at least a portion of the dirt collectionregion.

In some embodiments, the mechanical transfer member may be moveablealong a lower surface of the dirt collection region.

In some embodiments, the mechanical transfer mechanism may comprise amember that is moveable through the air treatment unit, whereby themechanical transfer mechanism pushes dirt through the air treatment unittowards a dirt outlet port of the air treatment unit.

In some embodiments, the mechanical transfer mechanism may be moveablethrough the air treatment unit and the dirt outlet port, whereby themechanical transfer mechanism pushes dirt through the air treatment unitand out the outlet port of the air treatment unit.

In some embodiments, the autonomous surface cleaning apparatus mayfurther comprise a disposable bag retaining member and wherein theautonomous surface cleaning apparatus is operable in a floor cleaningmode and a dirt emptying mode, and in the dirt emptying mode themechanical transfer member may be moveable in the first directionwhereby dirt is transferred into a disposable bag.

In some embodiments, the autonomous surface cleaning apparatus mayfurther comprise a navigation system and the autonomous surface cleaningapparatus may be operable to deposit the disposable bag containing thedirt in a predetermined location.

In some embodiments, the location may be adjacent a garbage receptacle.

In some embodiments, the autonomous surface cleaning apparatus mayfurther comprise a pneumatic dirt transfer mechanism.

In some embodiments, the pneumatic dirt transfer mechanism may comprisethe primary suction motor.

In some embodiments, the autonomous surface cleaning apparatus mayfurther comprise a secondary air flow path selectively connectable influid flow communication with the primary suction motor, the secondaryair flow path may extend between a downstream end of the primary suctionmotor and a dirt collection region of the air treatment unit.

In some embodiments, the first side may comprise a first side of thedirt collection region, the second side may comprise a second side ofthe dirt collection region, the mechanical transfer member may bemoveable in the first direction from the first side of the dirtcollection region towards the second side of the dirt collection regionand the secondary air flow path may extend between a downstream end ofthe primary suction motor he first side of the dirt collection.

In some embodiments, the autonomous surface cleaning apparatus mayfurther comprise a secondary air flow path in fluid flow communicationwith the dirt bin and the pneumatic dirt transfer mechanism may comprisea secondary suction motor provided in the secondary air flow path.

In another broad aspect of this disclosure, which may be used by itselfor with one or more of the other aspects disclosed herein, a mechanicaltransfer member may be provided inside of a robotic docking station andused to convey dirt that has been collected inside a robotic surfacecleaning apparatus into the robotic docking station. The mechanicaltransfer member may be moveable between a storage position and one ormore dirt emptying positions. In the storage position, the mechanicaltransfer member may be stored on or inside of the docking station. Inthe dirt emptying positions, the mechanical transfer member may moveablefrom the docking station, through a dirt outlet of an air treatment unitof the robotic surface cleaning apparatus, through at least a portion ofthe air treatment unit, and then reversed back into the docking stationso as to drag (e.g., pull) collected dirt out of the robot air treatmentunit into the docking station. Optionally, the docking station mayinclude a dirt receptacle for aggregating dirt removed from the roboticair treatment unit. An advantage of this design is again that thedocking station need not have a suction motor or an air treatment memberto filter dirt from the air drawn into the robotic docking station. Itwill be appreciated that this aspect may be combined with any other dirttransfer mechanism provided herein. It will be appreciated that such amechanical transfer member may be used by itself (e.g., it may be thesole dirt transfer mechanism) or it may be used with any other mechanismdisclosed herein or in use in the robotic docking station arts. Forexample, it may be used with a docking station that incorporates asuction fan to draw air through a dirt chamber of a robotic surfacecleaning apparatus.

In accordance with this broad aspect, there is provided an apparatuscomprising a docking station and an autonomous surface cleaningapparatus wherein, the autonomous surface cleaning apparatus comprises:

-   -   (a) a primary air flow patent extending from a dirty air inlet        to a clean air outlet:    -   (b) a primary suction motor positioned in the primary air flow        path; and    -   (c) an air treatment unit positioned in the primary air flow        path, the air treatment unit comprising a dirt collection        region;    -   and wherein the docking station comprises a dirt receptacle and        a mechanical dirt transfer mechanism operable to transfer dirt        that has collected in the dirt collection region from the dirt        collection region to the dirt receptacle.

In some embodiments, the autonomous surface cleaning apparatus may bepositioned on a floor, the air treatment unit may have an upper side, alower side, a first end having a first side positioned between the upperand lower sides and a second end having a second side positioned betweenthe upper and lower sides, the second side is spaced apart from thefirst side in a first direction and, the mechanical transfer member maybe moveable in the first direction through at least a portion of the airtreatment unit whereby dirt collected in the air treatment unit is movedin the first direction through the air treatment unit.

In some embodiments, the autonomous surface cleaning apparatus may bepositioned on a floor, the air treatment unit may have an upper side, alower side, a first end having a first side positioned between the upperand lower sides and a second end having a second side positioned betweenthe upper and lower sides, the second side is spaced apart from thefirst side in a first direction, the second side has a dirt outlet and,in a dirt emptying mode, the mechanical transfer member may be moveablethrough the dirt outlet towards the first side and then moveable in thefirst direction back through the dirt outlet.

In some embodiments, the mechanical transfer member may comprise asweeping portion and a drive portion, the sweeping portion may bereconfigurable between an insertion position in which the sweepingportion is positioned above the lower side and a sweeping position inwhich the sweeping portion extends downwardly from the drive portion.

In some embodiments, the autonomous surface cleaning apparatus may havea robot bin door which closes the dirt outlet and the mechanical dirttransfer mechanism may open the robot bin door when the mechanical dirttransfer mechanism is actuated.

In some embodiments, the docking station may have an openable door whichcloses a dirt inlet of the dirt receptacle and the mechanical dirttransfer mechanism may open the openable door when the mechanical dirttransfer mechanism is actuated.

In some embodiments, the autonomous surface cleaning apparatus may havea robot bin door which closes the dirt outlet and the mechanical dirttransfer mechanism may open the robot bin door when the mechanical dirttransfer mechanism is actuated.

In some embodiments, the autonomous surface cleaning apparatus may havea robot bin door which closes the dirt outlet and the robot bin door maybe opened when the autonomous surface cleaning apparatus docks at thedocking station.

In some embodiments, the docking station may have an openable door whichcloses a dirt inlet of the dirt receptacle and the openable door may beopened when the autonomous surface cleaning apparatus docks at thedocking station.

In some embodiments, the autonomous surface cleaning apparatus may havea robot bin door which closes the dirt outlet and the robot bin door maybe opened when the autonomous surface cleaning apparatus docks at thedocking station.

In some embodiments, the autonomous surface cleaning apparatus may havea robot bin door which closes the dirt outlet and the robot bin door maybe opened when an emptying mode of the autonomous surface cleaningapparatus is actuated.

In some embodiments, the docking station may have an openable door whichcloses a dirt inlet of the dirt receptacle and the openable door may beopened when an emptying mode of the autonomous surface cleaningapparatus is actuated.

In some embodiments, the autonomous surface cleaning apparatus may havea robot bin door which closes the dirt outlet and the robot bin door mayopened when an emptying mode of the autonomous surface cleaningapparatus is actuated.

In some embodiments, the apparatus may further comprise a pneumatic dirttransfer mechanism.

In some embodiments, the autonomous surface cleaning apparatus may havethe pneumatic dirt transfer mechanism.

In some embodiments, the mechanical dirt transfer mechanism may beexterior to the dirt receptacle.

In accordance with another aspect, which may be used by itself or withone or more of the other aspects disclosed herein, a pneumatic dirttransfer mechanism may be provided inside of a robotic surface cleaningapparatus and operable in a dirt emptying mode to convey dirt that hasbeen collected inside the robotic surface cleaning apparatus to adocking station. In some cases, the pneumatic dirt transfer mechanismmay comprise the primary suction motor of the robotic surface cleaningapparatus. The suction motor may be operable between a floor cleaningmode and a dirt emptying mode. In the floor cleaning mode, the suctionmotor may be used to generate a suction air flow to facilitate cleaningand/or sweeping of dirt of a surface. The airflow generated by thesuction motor may travel through a primary air flow path extending froma dirty air inlet of the robotic surface cleaning apparatus to a cleanair outlet of the robotic surface cleaning apparatus. In the dirtemptying mode, the exhaust air flow, from the outlet of the suctionmotor of the robotic surface cleaning apparatus to the clean air outletmay be reconfigured, such as by a valve, to flow along a secondary airflow path to direct the exhaust air through part or all of the dirtstorage chamber or dirt bin of the robotic surface cleaning apparatusand into the docking station.

Alternatively, or in addition, in the dirt emptying mode, the directionof rotation of an internal fan blade, of the suction motor, may bereversed such that the inlet of the suction motor becomes a suctionmotor air outlet. In this configuration, in the dirt emptying mode, airmay be directed, such as via a secondary air flow path back through adirt storage chamber or dirt bin of the robotic surface cleaningapparatus, and into the docking station.

Alternatively, or in addition, the pneumatic transfer mechanism cancomprise a secondary suction motor provided with the robotic surfacecleaning apparatus, which is separate from the primary suction motor ofthe robotic surface cleaning apparatus used in the floor cleaning mode.The secondary suction motor may be positioned in a secondary air flowpath which extends between an air inlet and a dirt storage chamber ordirt bin of the robotic surface cleaning apparatus. The secondarysuction motor may be operated in a dirt emptying mode to push collecteddirt in a dirt storage chamber or dirt bin of the robotic vacuum cleanerinto a docking station.

In any such embodiment, the primary suction motor of the robotic surfacecleaning apparatus, and/or the secondary suction motor, as the case maybe, may be operated at a different, e.g., reduced, power level whenconveying or assisting in conveying dirt from the dirt storage chamberof a robotic surface cleaning apparatus into a docking station, duringoperation in the dirt emptying mode, compared to the power level of theprimary suction motor when the robotic surface cleaning apparatusoperates in a floor cleaning mode. An advantage of such a design is thatthe docking station need not have a suction motor.

It will be appreciated that such a pneumatic transfer member may be usedby itself (e.g., it may be the sole dirt transfer mechanism) or it maybe used with any other mechanism disclosed herein or in use in therobotic docking station arts. For example this aspect may be combinedwith mechanically conveying dirt from the dirt storage chamber of arobotic surface cleaning apparatus into a docking station and/or it maybe used with a docking station that incorporates a suction fan to drawair through a dirt chamber of a robotic surface cleaning apparatus.

In accordance with this broad aspect, there is provided an autonomoussurface cleaning apparatus comprising:

-   -   (a) a primary air flow path extending from a dirty air inlet to        a clean air outlet:    -   (b) a primary suction motor positioned in the primary air flow        path;    -   (c) an air treatment unit positioned in the primary air flow        path, the air treatment unit comprising a dirt collection region        wherein, when the autonomous surface cleaning apparatus is        positioned on a floor, the dirt collection region has an upper        side, a lower side, a first end having a first side positioned        between the upper and lower sides and a second end having a        second side positioned between the upper and lower sides, the        second side is spaced apart from the first side in a first        direction, the first side has a dirt collection region air inlet        port and the second side has a dirt outlet; and,    -   (d) a pneumatic dirt transfer member is operable in a dirt        emptying mode to produce an air flow which enters the dirt        collection region through the dirt collection region air inlet        port and whereby dirt collected in the dirt collection region is        moved in the first direction through the dirt outlet.

In some embodiments, the pneumatic dirt transfer mechanism may comprisethe primary suction motor.

In some embodiments, a secondary air flow path may be selectivelyconnectable in fluid flow communication with the primary suction motor,the secondary air flow path may extend between a downstream end of theprimary suction motor and the dirt collection region air inlet port.

In some embodiments, the autonomous surface cleaning apparatus may beoperable in a floor cleaning mode and a dirt emptying mode, in the floorcleaning mode, air may travel through the primary air flow path and inthe dirt emptying mode, the secondary air flow path may be connected influid flow communication with the primary suction motor and air maytravel from the primary suction motor to the dirt collection region airinlet port and exit the dirt collection region through the dirt outlet.

In some embodiments, the dirt outlet which communicates with a dockingstation when the autonomous surface cleaning apparatus is docked at thedocking station and in the dirt emptying mode, the air may travel fromthe primary suction motor to the dirt collection region air inlet port,through the dirt collection region, through the dirt outlet, through adirt inlet of the docking station and out a clean air outlet of thedocking station.

In some embodiments, the autonomous surface cleaning apparatus may beoperable in a floor cleaning mode and a dirt emptying mode, in the floorcleaning mode air may travel through the primary air flow path and inthe dirt emptying mode air may travel through the secondary air flowpath, and the autonomous surface cleaning apparatus may further comprisea valve operable between a floor cleaning position in which the primarysuction motor is in fluid flow communication with the clean air outletand a dirt emptying position in which the primary suction motor is influid flow communication with the dirt collection region air inlet.

In some embodiments, the pneumatic dirt transfer mechanism may comprisea secondary suction motor provided in a secondary air flow path, whereinthe autonomous surface cleaning apparatus may be operable in a floorcleaning mode and a dirt emptying mode, in the floor cleaning mode, airmay travel through the primary air flow path and in the dirt emptyingmode the secondary air flow path may be in fluid flow communication withthe dirt collection region.

In some embodiments, the dirt collection region may have an air outletand a portion of the primary air flow path may extend from the airoutlet of the dirt collection region to the clean air outlet and, in thedirt emptying mode the portion of the primary air flow path may beclosed.

In some embodiments, the dirt collection region may have a dirt inletand a first portion of the primary air flow path may extend from thedirty air inlet to the dirt inlet of the dirt collection region and, inthe dirt emptying mode the portion of the primary air flow path may beclosed.

In some embodiments, the dirt collection region may have an air outletand a second portion of the primary air flow path may extend from theair outlet of the dirt collection region to the clean air outlet and, inthe dirt emptying mode the second portion of the primary air flow pathmay be closed.

In accordance with this broad aspect, there is also provided anautonomous surface cleaning apparatus comprising:

-   -   (a) a primary air flow path extending from a dirty air inlet to        a clean air outlet:    -   (b) a primary suction motor positioned in the primary air flow        path;    -   (c) an air treatment unit positioned in the primary air flow        path, the air treatment unit comprising a dirt collection region        having a dirt inlet, a dirt collection region air inlet port and        a dirt outlet; and,    -   (d) a secondary air flow path extending from a secondary air        flow path air inlet to the dirt outlet of the dirt collection        region;    -   (e) a secondary suction motor positioned in the secondary air        flow path,        wherein the autonomous surface cleaning apparatus is operable in        a floor cleaning mode and a dirt emptying mode, in the floor        cleaning mode, air travels through the primary air flow path and        in the dirt emptying mode the secondary air flow path is in        fluid flow communication with the dirt collection region whereby        air enters the dirt collection region through the dirt        collection region air inlet and dirt collected in the dirt        collection region is moved through the dirt outlet.

In some embodiments, the secondary suction motor may draw air throughthe dirt collection region air inlet into the dirt collection region andout the dirt outlet.

In some embodiments, the secondary suction motor may blow air throughthe dirt collection region air inlet into the dirt collection region andout the dirt outlet.

In some embodiments, the dirt collection region may have a primary airflow path air outlet and, in the floor cleaning mode, air may travelthrough a first portion of the primary air flow path extending from thedirty air inlet to the dirt inlet of the dirt collection region andthrough a second portion of the primary air flow path extending from theprimary air flow path air outlet to the clean air outlet.

In some embodiments, in the dirt emptying mode, at least one of thefirst and second portions may be closed.

In some embodiments, in the dirt emptying mode, each of the first andsecond portions may be closed.

In some embodiments, in the floor cleaning mode, the secondary air flowpath may be closed.

In accordance with this broad aspect, there is also provided, anautonomous surface cleaning apparatus comprising:

-   -   (a) a primary air flow path extending from a dirty air inlet to        a clean air outlet:    -   (b) a suction motor positioned in the primary air flow path;    -   (c) an air treatment unit positioned in the primary air flow        path, the air treatment unit comprising a dirt collection region        having a dirt inlet, a dirt collection region air inlet port and        a dirt outlet; and,    -   (d) a secondary air flow path extending from the suction motor        to the dirt outlet of the dirt collection region;        wherein the autonomous surface cleaning apparatus is operable in        a floor cleaning mode and a dirt emptying mode, in the floor        cleaning mode, the suction motor drives a fan blade in a first        direction of rotation and air travels through the primary air        flow path and, in the dirt emptying mode, the suction motor        drives a fan blade in a second direction of rotation whereby air        enters the dirt collection region through the dirt collection        region air inlet and dirt collected in the dirt collection        region is moved through the dirt outlet.

In accordance with another aspect, which may be used by itself or withone or more of the other aspects disclosed herein, a pneumatic dirttransfer mechanism may be provided inside a robotic docking station andoperable in a dirt emptying mode to direct air to the robotic surfacecleaning apparatus to thereby convey dirt that has been collected insidethe robotic surface cleaning apparatus to the docking station. Thepneumatic dirt transfer mechanism may comprise a suction motor providedon or inside of the docking station and an air flow path extendingbetween a downstream end of the docking station suction motor and thedirt collection region of the autonomous surface cleaning apparatus,when the autonomous cleaning apparatus is docked at the docking station.In a dirt emptying mode, the docking station suction motor may directair into the autonomous surface cleaning apparatus so as to transferdirt that has collected inside the dirt collection region to a dirtreceptacle of the docking station. An advantage of such a design is thatby providing the pneumatic dirt transfer mechanism inside the dockingstation, a dirt transfer mechanism is not required to be provided insideof the robotic vacuum cleaner. This, in turn, may simplify the design ofthe robotic vacuum cleaner. Further, directing air through the dirtchamber of a robotic surface cleaning apparatus may more completelyempty the dirt chamber.

It will be appreciated that such a pneumatic transfer member may be usedby itself (e.g., it may be the sole dirt transfer mechanism) or it maybe used with any other mechanism disclosed herein or in use in therobotic docking station arts. For example, it may be used with a dirttransfer mechanism provided inside the robotic vacuum cleaner to providemore efficient dirt transfer between the robotic vacuum cleaner and thedocking station. The pneumatic transfer mechanism may also be providedat a connection interface of the docking station.

In accordance with this broad aspect, there is provided an apparatuscomprising a docking station having a dirt receptacle and an autonomoussurface cleaning apparatus, wherein the autonomous surface cleaningapparatus comprises:

-   -   (a) a primary air flow path extending from a dirty air inlet to        a clean air outlet:    -   (b) a primary suction motor positioned in the primary air flow        path; and    -   (c) an air treatment unit positioned in the primary air flow        path, the air treatment unit comprising a dirt collection        region;        wherein the apparatus comprises a pneumatic dirt transfer        mechanism comprising a secondary air flow path and a secondary        suction motor provided in the secondary air flow path, and        wherein the secondary air flow path extends between a downstream        end of the secondary suction motor and the dirt collection        region of the autonomous surface cleaning apparatus whereby in a        dirt emptying mode the secondary suction motor directs air into        the autonomous surface cleaning apparatus so as to transfer dirt        that has collected in the dirt collection region from the dirt        collection region to the dirt receptacle, and        wherein a portion of the pneumatic dirt transfer mechanism is        provided in the docking station.

In some embodiments, the secondary suction motor may be provided in thedocking station.

In some embodiments, the secondary suction motor may be provided in theautonomous surface cleaning apparatus.

In some embodiments, the docking station may have a secondary air flowpath air outlet port and the autonomous surface cleaning apparatus mayhave a secondary air flow path air inlet port which mates with thesecondary air flow path air outlet port of the docking station when theautonomous surface cleaning apparatus docks at the docking station.

In some embodiments, the secondary suction motor may draw from the dirtcollection region.

In some embodiments, the secondary suction motor may blow into the dirtcollection region.

In some embodiments, the autonomous surface cleaning apparatus may bepositioned on a floor, the dirt collection region may have an upperside, a lower side, a first end having a first side positioned betweenthe upper and lower sides and a second end having a second sidepositioned between the upper and lower sides, the second side is spacedapart from the first side in a first direction, the first side has adirt collection region air inlet port and the second side has a dirtoutlet and wherein, in the dirt emptying mode, the secondary suctionmotor may produce an air flow that enters the dirt collection regionthrough the dirt collection region air inlet port and exits through thedirt outlet.

In some embodiments, the dirt collection region may have an air outletand a portion of the primary air flow path my extend from the air outletof the dirt collection region to the clean air outlet and, in the dirtemptying mode the portion of the primary air flow path may be closed.

In some embodiments, the dirt collection region may have a dirt inletand a first portion of the primary air flow path may extend from thedirty air inlet to the dirt inlet of the dirt collection region and, inthe dirt emptying mode the portion of the primary air flow path may beclosed.

In some embodiments, the dirt collection region may have an air outletand a second portion of the primary air flow path may extend from theair outlet of the dirt collection region to the clean air outlet and, inthe dirt emptying mode the second portion of the primary air flow pathmay be closed.

In accordance with this broad aspect, there is also provided anapparatus comprising a docking station having a dirt receptacle and anautonomous surface cleaning apparatus, wherein the autonomous surfacecleaning apparatus comprises:

-   -   (a) a primary air flow path extending from a dirty air inlet to        a clean air outlet:    -   (b) a primary suction motor positioned in the primary air flow        path; and    -   (c) an air treatment unit positioned in the primary air flow        path, the air treatment unit comprising a dirt collection region        wherein, when the autonomous surface cleaning apparatus is        positioned on a floor, the dirt collection region has an upper        side, a lower side, a first end having a first side positioned        between the upper and lower sides and a second end having a        second side positioned between the upper and lower sides, the        second side is spaced apart from the first side in a first        direction, the first side has a dirt collection region air inlet        port and the second side has a dirt outlet, and        wherein the apparatus comprises a pneumatic dirt transfer        mechanism comprising a secondary air flow path, and the        secondary air flow path comprises a portion that extends in a        downstream direction from the docking station to the dirt        collection region, and        wherein, in the dirt emptying mode, air travels through the        secondary air flow path and enters the dirt collection region        through the dirt collection region air inlet port and exits        through the dirt outlet.

In some embodiments, the apparatus may further comprise a secondarysuction motor.

In some embodiments, the secondary suction motor may be provided in thedocking station.

In some embodiments, the dirt collection region may have an air outletand a portion of the primary air flow path may extend from the airoutlet of the dirt collection region to the clean air outlet and, in thedirt emptying mode the portion of the primary air flow path may beclosed.

In some embodiments, the dirt collection region may have a dirt inletand a first portion of the primary air flow path may extend from thedirty air inlet to the dirt inlet of the dirt collection region and, inthe dirt emptying mode the portion of the primary air flow path may beclosed.

In some embodiments, the dirt collection region may have an air outletand a second portion of the primary air flow path may extend from theair outlet of the dirt collection region to the clean air outlet and, inthe dirt emptying mode the second portion of the primary air flow pathmay be closed.

In accordance with this broad aspect, there is also provided anapparatus comprising a docking station having a dirt receptacle and anautonomous surface cleaning apparatus, wherein the autonomous surfacecleaning apparatus comprises:

-   -   (a) a primary air flow path extending from a dirty air inlet to        a clean air outlet:    -   (b) a suction motor positioned in the primary air flow path; and    -   (c) an air treatment unit positioned in the primary air flow        path, the air treatment unit comprising a dirt collection        region,        wherein the apparatus comprises a pneumatic dirt transfer        mechanism comprising a secondary air flow path that comprises a        first portion that extends between the dirt receptacle and the        suction motor and a second portion that extends between the        suction motor and the dirt collection region of the autonomous        surface cleaning apparatus whereby in a dirt emptying mode the        suction motor draws air from the dirt receptacle to the suction        motor and directs air into the dirt collection region of the        autonomous surface cleaning apparatus whereby dirt that has        collected in the dirt collection region is transferred from the        dirt collection region to the dirt receptacle.

In some embodiments, the dirt collection region may have an air outletand a portion of the primary air flow path may extend from the airoutlet of the dirt collection region to the clean air outlet and, in thedirt emptying mode the portion of the primary air flow path may beclosed.

In some embodiments, the dirt collection region may have a dirt inletand a first portion of the primary air flow path may extend from thedirty air inlet to the dirt inlet of the dirt collection region and, inthe dirt emptying mode the portion of the primary air flow path may beclosed.

In some embodiments, the dirt collection region may have an air outletand a second portion of the primary air flow path may extend from theair outlet of the dirt collection region to the clean air outlet and, inthe dirt emptying mode the second portion of the primary air flow pathmay be closed.

It will be appreciated by a person skilled in the art that an apparatusor method disclosed herein may embody any one or more of the featurescontained herein and that the features may be used in any particularcombination or sub-combination.

These and other aspects and features of various embodiments will bedescribed in greater detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the described embodiments and to show moreclearly how they may be carried into effect, reference will now be made,by way of example, to the accompanying drawings in which:

FIG. 1 is a perspective view of a robotic vacuum cleaner docked at adocking station;

FIG. 2 is a perspective view of the robotic vacuum cleaner of FIG. 1;

FIG. 3 is a cross-sectional view of the robotic vacuum cleaner of FIG.1, taken along the section line 3-3′ of FIG. 2;

FIG. 4A is a simplified representation of the cross-sectional view ofFIG. 3, according to some embodiments;

FIG. 4B is a simplified representation of the cross-sectional view ofFIG. 3, and showing a dirt bin of the robotic vacuum cleaner removedfrom the robotic vacuum cleaner housing;

FIG. 4C is a perspective top-front view of the removable dirt bin ofFIG. 4B;

FIG. 4D is a perspective rear-bottom view of the removable dirt bin ofFIG. 4B;

FIG. 5A is a perspective view of a robotic vacuum cleaner docked at adocking station, and showing a top openable lid of the docking stationin an opened position;

FIG. 5B is a perspective view of the robotic vacuum cleaner docked at adocking station, and showing a dirt receptacle being removed from thedocking station;

FIG. 5C is a perspective view of the robotic vacuum cleaner docked atthe docking station, in accordance with an alternate embodiment;

FIG. 6A is a side cross-sectional view of the robotic vacuum cleaner anddocking station of FIG. 5C, taken along the section line 6-6′ of FIG.5C, and showing both the docking station door and the robotic vacuumcleaner dirt bin door in a closed position;

FIG. 6B is a side cross-sectional view of the robotic vacuum cleaner anddocking station of FIG. 6A, and showing both the docking station doorand the robotic vacuum cleaner dirt bin door in an open position;

FIG. 6C is a side cross-sectional view of an alternate embodiment of therobotic vacuum cleaner and docking station of FIG. 6A, taken along thesection line 6-6′ of FIG. 5C, showing the dirt receptacle door and therobotic vacuum cleaner dirt bin door in an open position;

FIG. 7A is a side cross-sectional view, taken along section line 7-7′ ofFIG. 5C, of the robotic vacuum cleaner un-docked from the dockingstation, and showing the robot dirt bin door and the docking stationdoor in a closed position, in accordance with a further alternateembodiment;

FIG. 7B is a side cross-sectional view of the robotic vacuum cleanerdocked at the docking station, and showing the robot dirt bin door andthe docking station door in an open position;

FIG. 7C is a perspective view of the door opening mechanism for therobot dirt bin door of FIG. 7A;

FIG. 8A is a side cross-sectional view, taken along section line 7-7′ ofFIG. 5C, of the robotic vacuum cleaner docked at the docking station,and showing the robot dirt bin door and docking station door in an openposition, in accordance with another embodiment;

FIG. 8B is a perspective view of the door opening mechanism for therobot dirt bin door of FIG. 8A;

FIG. 9A is a side cross-sectional view, taken along section line 7-7′ ofFIG. 5C, of the robotic vacuum cleaner docked at the docking station,and showing the robot dirt bin door and docking station door in an openposition, in accordance with a further alternate embodiment;

FIG. 9B is a perspective view of the door opening mechanism for therobot dirt bin door of FIG. 9A;

FIG. 10A is a side cross-sectional view of the robotic vacuum cleaner,taken along sectional line 10-10′ of FIG. 5C, and showing a mechanicaldirt transfer mechanism in a floor cleaning or storage position, inaccordance with a further alternate embodiment;

FIG. 10B is a side cross-sectional view of the robotic vacuum cleaner inFIG. 10A docked at a docking station, taken along sectional line 10-10′of FIG. 5C, and showing the mechanical dirt transfer mechanism in a dirtemptying position;

FIG. 10C is a side cross-sectional view of the robotic vacuum cleanerand docking station of FIG. 10B, and showing the mechanical dirttransfer mechanism in a further dirty emptying position;

FIG. 11A is a perspective view of a robot dirt bin in the robotic vacuumcleaner of FIG. 10A, and showing the mechanical dirt transfer mechanismin the storage or floor cleaning position, in accordance with a furtheralternate embodiment;

FIG. 11B is a perspective view of the robot dirt bin of FIG. 11A, andshowing the mechanical dirt transfer mechanism in a dirt emptyingposition;

FIG. 11C is a perspective view of a robot dirt bin of FIG. 11A, andshowing the mechanical dirt transfer mechanism in a further dirtemptying position;

FIG. 11D is a perspective view of an example mechanical transfer member;

FIG. 12A is a side cross-sectional view of the robotic vacuum cleaner,taken along sectional line 10-10′ of FIG. 5C, and showing the mechanicaldirt transfer mechanism in a storage or floor cleaning position, inaccordance with a further alternate embodiment;

FIG. 12B is a side cross-sectional view of the robotic vacuum cleaner ofFIG. 12A, docked at a docking station, and showing the mechanical dirttransfer mechanism in a dirt emptying position;

FIG. 12C is a perspective view of a mechanical actuation mechanism usedin the robotic vacuum cleaner of FIGS. 12A and 12B;

FIG. 13A is a side cross-sectional view of the robotic vacuum cleaner,taken along sectional line 10-10′ of FIG. 5C, and showing a mechanicaldirt transfer mechanism in a storage or floor cleaning position, inaccordance with a further alternate embodiment;

FIG. 13B is a side cross-sectional view of the robotic vacuum cleaner ofFIG. 13A, docked at a docking station, and showing the mechanical dirttransfer mechanism in dirt emptying position;

FIG. 13C is a perspective view of a mechanical actuation mechanism usedin the robotic vacuum cleaner of FIGS. 13A and 13B;

FIG. 14A is a side cross-sectional view of the robotic vacuum cleaner,taken along sectional line 10-10′ of FIG. 5C, and showing a mechanicaldirt transfer mechanism in a storage or floor cleaning position, inaccordance with a further alternate embodiment;

FIG. 14B is a side cross-sectional view of the robotic vacuum cleaner ofFIG. 14A, docked at a docking station, and showing the mechanical dirttransfer mechanism in a dirt emptying position;

FIG. 15A is a side cross-sectional view of a robotic vacuum cleanerdocked at a docking station, taken along sectional line 10-10′ of FIG.5C, and showing a mechanical dirt transfer mechanism located inside thedocking station in a storage position;

FIG. 15B illustrates the side cross-sectional view of FIG. 15A, andshowing the mechanical dirt transfer mechanism in a dirt emptyingposition;

FIG. 15C illustrates the side cross-sectional view of FIG. 15A, andshowing the mechanical dirt transfer mechanism in a further dirt emptiedposition;

FIG. 15D illustrates the side cross-sectional view of FIG. 15A, andshowing the mechanical dirt transfer mechanism in a partially retracteddirt emptying position;

FIG. 15E illustrates the side cross-sectional view of FIG. 15A, andshowing the mechanical dirt transfer mechanism in a further retracteddirt emptying position;

FIG. 16A is a perspective view of a foldable sweeper in an insertionposition;

FIG. 16B is a perspective view of the foldable sweeper in a sweepingposition;

FIG. 17A is a side cross-sectional view of an alternate embodiment of arobotic vacuum cleaner, taken along sectional line 10-10′ of FIG. 5C,and showing a suction motor in a floor cleaning mode;

FIG. 17B is a side cross-sectional view, taken along sectional line10-10′ of FIG. 5C, of the robotic vacuum cleaner of FIG. 17A, docked ata docking station, and showing the suction motor in a dirt emptyingmode;

FIG. 17C is a perspective view of a butterfly valve in an open position;

FIG. 17D is a perspective view of the butterfly valve of FIG. 17C in aclosed position;

FIG. 18A is a side cross-sectional view of a robotic vacuum cleaner,taken along sectional line 10-10′ of FIG. 5C, showing a suction motor ofthe robotic vacuum cleaner operating in a floor cleaning mode, inaccordance with an alternate embodiment;

FIG. 18B is a side cross-sectional view of the robotic vacuum cleaner ofFIG. 18A, docked at a docking station, and showing the suction motoroperating in a dirt emptying mode;

FIG. 19A is a side cross-sectional view of a robotic vacuum cleaner,taken along sectional line 10-10′ of FIG. 5C, in accordance with afurther alternate embodiment, and showing a suction motor of the roboticvacuum cleaner operating in a floor cleaning mode;

FIG. 19B is a side cross-sectional view of a robotic vacuum cleaner ofFIG. 19A, docked at a docking station, taken along sectional line 10-10′of FIG. 5C, and showing the suction motor operating in a dirt emptyingmode;

FIG. 19C is a top-side perspective view of the robotic vacuum cleanerand docking station of FIG. 19B;

FIG. 20A is a side cross-sectional view of a robotic vacuum cleanerdocked at a docking station, taken along sectional line 10-10′ of FIG.5C, and showing a secondary suction motor located inside of the roboticvacuum cleaner and being operated in a dirt emptying mode, in accordancewith a further alternate embodiment;

FIG. 20B is a side cross-sectional view of a robotic vacuum cleanerdocked at a docking station, taken along sectional line 10-10′ of FIG.5C, and showing a secondary suction motor located inside of the roboticvacuum cleaner and being operated in a dirt emptying mode, in accordancewith a further alternate embodiment;

FIG. 21A is a side cross-sectional view of a robotic vacuum cleaner,taken along sectional line 10-10′ of FIG. 5C, in accordance with afurther alternate embodiment;

FIG. 21B is a side cross-sectional view of the robotic vacuum cleaner ofFIG. 21A, docked at a docking station, and showing a suction motorprovided inside the docking station being operated in a dirt emptyingmode;

FIG. 22A is a side cross-sectional view of an un-docked robotic vacuumcleaner and docking station, taken along sectional line 10-10′ of FIG.5C, and showing the robotic vacuum cleaner being operated in a floorcleaning mode, according to a further alternate embodiment;

FIG. 22B is a side cross-sectional view of the robotic vacuum cleanerand docking station of FIG. 22A, and showing the robotic vacuum cleanerdocked at the docking station, and a suction motor provided inside thedocking station being operated in a dirt emptying mode;

FIG. 23 is a side cross-sectional view of a robotic vacuum cleanerdocked at a docking station, taken along sectional line 10-10′ of FIG.5C, and showing a suction motor provided inside the docking stationbeing operated in a dirt emptying mode, according to a further alternateembodiment;

FIG. 24A is a side cross-sectional view of a robotic vacuum cleanerdocked at a docking station, taken along sectional line 10-10′ of FIG.5C, and showing a suction motor provided inside of a connectioninterface and being operated in a dirt emptying mode, according to afurther alternate embodiment;

FIG. 24B is a side cross-sectional view of the robotic vacuum cleanerand docking station of FIG. 24A, and showing the robotic vacuum cleanerun-docking from the docking station and the suction motor providedinside of the connection interface being operated in a dust absorptionmode;

FIG. 25 is a side cross-sectional view of a robotic vacuum cleanerdocked at a docking station, taken along sectional line 10-10′ of FIG.5C, and showing a suction motor provided inside of a connectioninterface being operated in a dirt emptying mode, according to a furtheralternate embodiment;

FIG. 26 is a side cross-sectional view of a robotic vacuum cleanerdocked at a docking station, taken along sectional line 10-10′ of FIG.5C, and showing a suction motor provided inside of a connectioninterface being operated in a dirt emptying mode, according to a furtheralternate embodiment;

FIG. 27 is a side cross-sectional view of a robotic vacuum cleanerdocked at a docking station, taken along sectional line 10-10′ of FIG.5C, and showing a suction motor provided inside of a connectioninterface being operated in a dirt emptying mode, according to a furtheralternate embodiment;

FIG. 28 is a side cross-sectional view of a robotic vacuum cleanerdocked at a docking station, taken along sectional line 10-10′ of FIG.5C, and showing a suction motor provided inside of a connectioninterface being operated in a dirt emptying mode, according to a furtheralternate embodiment;

FIG. 29A is a side cross-sectional view of a robotic vacuum cleaner anddocking station, taken along sectional line 10-10′ of FIG. 5C, showingthe robotic vacuum cleaner un-docked from the docking station andoperating in a floor cleaning mode, according to a further alternateembodiment; and,

FIG. 29B is a side cross-sectional view of the robotic vacuum cleanerand docking station of FIG. 29A, and showing the robotic vacuum cleanerdocked at the docking station and a suction motor provided inside of aconnection interface being operated in a dirt emptying mode.

The drawings included herewith are for illustrating various examples ofarticles, methods, and apparatuses of the teaching of the presentspecification and are not intended to limit the scope of what is taughtin any way.

DESCRIPTION OF VARIOUS EMBODIMENTS

Various apparatuses or processes will be described below to provide anexample of an embodiment of each claimed invention. No embodimentdescribed below limits any claimed invention and any claimed inventionmay cover processes or apparatuses that differ from those describedbelow. The claimed inventions are not limited to apparatuses orprocesses having all of the features of any one apparatus or processdescribed below or to features common to multiple or all of theapparatuses described below. It is possible that an apparatus or processdescribed below is not an embodiment of any claimed invention. Anyinvention disclosed in an apparatus or process described below that isnot claimed in this document may be the subject matter of anotherprotective instrument, for example, a continuing patent application, andthe applicants, inventors or owners do not intend to abandon, disclaimor dedicate to the public any such invention by its disclosure in thisdocument.

The terms “an embodiment,” “embodiment,” “embodiments,” “theembodiment,” “the embodiments,” “one or more embodiments,” “someembodiments,” and “one embodiment” mean “one or more (but not all)embodiments of the present invention(s),” unless expressly specifiedotherwise.

The terms “including,” “comprising” and variations thereof mean“including but not limited to,” unless expressly specified otherwise. Alisting of items does not imply that any or all of the items aremutually exclusive, unless expressly specified otherwise. The terms “a,”“an” and “the” mean “one or more,” unless expressly specified otherwise.

As used herein and in the claims, two or more parts are said to be“coupled”, “connected”, “attached”, or “fastened” where the parts arejoined or operate together either directly or indirectly (i.e., throughone or more intermediate parts), so long as a link occurs. As usedherein and in the claims, two or more parts are said to be “directlycoupled”, “directly connected”, “directly attached”, or “directlyfastened” where the parts are connected in physical contact with eachother. As used herein, two or more parts are said to be “rigidlycoupled”, “rigidly connected”, “rigidly attached”, or “rigidly fastened”where the parts are coupled so as to move as one while maintaining aconstant orientation relative to each other. None of the terms“coupled”, “connected”, “attached”, and “fastened” distinguish themanner in which two or more parts are joined together.

Some elements herein may be identified by a part number, which iscomposed of a base number followed by an alphabetical orsubscript-numerical suffix (e.g. 112 a, or 112 ₁). Multiple elementsherein may be identified by part numbers that share a base number incommon and that differ by their suffixes (e.g. 112 ₁, 112 ₂, and 112 ₃).All elements with a common base number may be referred to collectivelyor generically using the base number without a suffix (e.g. 112).

General Description of an Autonomous Surface Cleaning Apparatus andDocking Station

With reference to FIGS. 1-3, the following is a general discussion ofembodiments of an apparatus 100, which provides a basis forunderstanding several features that are discussed herein. As discussedsubsequently, each of the features may be used individually or in anyparticular combination or sub-combination such as in the embodimentsdisclosed herein.

As exemplified, apparatus 100 includes an autonomous surface cleaningapparatus 104 and a docking station 108. In the course of cleaning, andduring periods of inactivity, the robotic vacuum cleaner 104 may, attimes, dock (or connect) to the docking station 108 (FIG. 1). Thedocking station 108 can facilitate quick emptying of the robotic vacuumcleaner 104 from dirt and debris accumulated therein during a cleaningoperation. Once some, or all, of the dust or collected debris (which maybe referred to as dirt) has been transferred out of the robotic vacuumcleaner, the docking station may be independently cleaned-out. In thismanner, the docking station 108 facilitates safe and fast emptying ofthe robotic surface cleaning device without requiring a user to, e.g.,remove a dirt collection container from the robotic vacuum cleaner eachtime it is desired to empty out dust and debris. In various cases,docking station 108 can also be used to re-charge a battery of therobotic vacuum cleaner 104 during docking.

General Description of an Autonomous Surface Cleaning Apparatus

The autonomous surface cleaning apparatus (also referred to herein as arobotic vacuum cleaner) may be of any shape and configuration. Asexemplified in FIGS. 2 and 3, the robotic vacuum cleaner 104 may have ahousing 140 defined by a generally circular configuration, andcomprising an upper end 144, a lower end 148 and peripheral side edge152 extending between the upper and lower ends 144, 148. A portion ofthe side edge 152 may define the front end 156 and another portion ofthe side edge 152 may define the rear end 160 of the robotic vacuumcleaner 104. One or more wheels 208 may be provided, at a lower end 148of the vacuum housing 140, for moving the robotic vacuum cleaner 104over surfaces requiring cleaning. It will be appreciated that, in otherembodiments, housing 140 may not have a circular configuration, but haveany other suitable design or shape.

In order to transfer dirt to docking station 108, robotic vacuum cleaner104 is provided with a dirt outlet 168. As exemplified, dirt outlet 168is provided at a front end 156 of the robot housing 140. As exemplifiedin FIG. 3, dirt outlet 168 is in fluid communication with an airtreatment unit 175 located inside the robot housing 140. In otherembodiments, the outlet port 168 can be provided at other locationsaround robot housing 140, including at a rear end 160, top end 144 orlower end 148 of housing 140. Further, more than one dirt outlet port168 can be provided on the vacuum 104. In embodiments exemplifiedherein, dirt outlet 168 may be removably coupled to a dirt inlet of thedocking station 108 to allow transfer of dirt and debris, collectedinside of air treatment unit 175, to docking station 108.

As exemplified, robotic vacuum cleaner 104 has an air treatment unit175. In the exemplified embodiment, the air treatment unit 175 includesa robot dirt collection chamber 176 (also referred to herein as a robotdirt bin 176 or a robot dirt collection region 176) for storing dirtcollected by the robotic vacuum cleaner 104 during the course ofcleaning. It will be appreciated that in alternate embodiments, arobotic vacuum cleaner 104 may have two or more dirt bins or dirtcollection chambers 176.

It will be appreciated that the air treatment unit 175 may use any airtreatment elements known in the air/dirt separation arts for treating anin-flow of dirty air and otherwise separating the air flow fromair-entrained dirt and may have one or more air treatment elements. Forexample, the air treatment element may be a cyclone, a momentumseparator, a bag or the like.

Robot dirt bin 176 may be of any configuration. As exemplified in FIGS.3 and 4C, robot dirt bin 176 may be generally flat and may have agenerally rectangular configuration. As exemplified, robot dirt bin 176extends in the longitudinal direction indicated by the longitudinal axis138, between a front end 176 a and an axially opposed rear end 176 b.When robotic vacuum cleaner 104 is placed on a horizontal surface, robotdirt bin 176 comprises a top end 176 c, a bottom end 176 d, and one ormore side faces 176 e extending between the top and bottom ends. In theexemplified embodiment, the front end 176 a of the dirt bin 176 maycomprise an at least partially open end defining a dirt outlet of therobot dirt bin which is aligned with dirt outlet port 168 of the robotichousing 140. In other embodiments, the rear end 176 b (FIG. 11D) or topend 176 b of the dirt bin 176 may also comprise an at least partiallyopen end.

If a docking station 108 is provided for receiving dirt collected by arobotic vacuum cleaner 104, then the robot dirt bin 176 may be securedin position in the robot housing 140 such that it is not intended to beuser removable (see for example FIG. 3).

Optionally, whether or not a docking station 108 is provided, robot dirtbin 176 may comprise a separate removable compartment (as exemplified inFIGS. 4A-4D). An advantage of this design is that the robot dirt bin maybe removed from the robotic vacuum cleaner 104 for cleaning (e.g., withwater). As exemplified, dirt bin 176 is removably disposed inside of acavity 220, formed within the robot body 140 (FIGS. 4A and 4B). Also, auser may extract the bin 176 to empty its contents (e.g., in a garbagereceptacle), without necessitating the use of a docking station 108.

The robot dirt bin 176 may be removable from robotic vacuum cleaner 104in any manner, for example, it may be removed by opening a doorprovided, e.g., on upper end 144 of housing 140 and removing the robotdirt bin 176 upwardly. Alternately, the robot dirt bin may be translatedhorizontally. In the exemplified embodiment, the dirt bin 176 is removed(i.e., extracted) from the cavity 220, through an outlet port 168 (FIG.4B), by translating the robot dirt bin 176 along a horizontallongitudinal axis 138.

In order to retain dirt in robot dirt bin 176, one or more openabledoors 212 may be provided. The openable doors 212 may be part of robotdirt bin 176 or they may be part of housing 140. When the openable doors212 are in a closed position, dirt is securely stored in robot dirt bin176. When at least one of the openable doors 212 is opened, robot dirtbin 176 may be emptied. The robot bin doors 212 can have any suitabledesign or configuration, and may be rotatably openable, translatable toan open position or the like. As exemplified in FIG. 3, door 212 ispivotally connected to the robot body 140 while, as exemplified inexemplified in FIGS. 4A-4C, door 212 is pivotally connected to the dirtbin 176 body.

In the embodiment exemplified in FIG. 4C, the door 212 is pivotallymounted to the robot dirt bin 176 by a hinge 216. Hinge 216 may beconfigured as a piano hinge, which rotates about an axis 224, transverseto axis 138 (FIG. 4C). In the exemplified embodiment, hinge 216 isprovided at a top-forward edge of dirt bin 176, and can be configured topivot the door 212 forwardly (see for example FIG. 4C) or rearwardly(see for example FIG. 15C). In other cases, hinge 216 can be located,for example, at the lower front edge of dirt bin 176.

Any number of openable doors 212 may be provided, and may be provided atany location on robot dirt bin 176. For example, the robot dirt bin maycomprise a single door (FIG. 4), or more than one door (FIG. 10). Inparticular, as exemplified in FIGS. 4A-4C, the front end 176 a of robotdirt bin 176 may comprise an openable end that is in communication withthe dirt outlet 168. The openable door 212 is provided at the front end176 a, and aligned with the outlet port 168, to seal the dirt bin 176during operation of the robotic vacuum cleaner 104. In otherembodiments, provided in further detail herein, and as exemplified inFIG. 10, dirt bin 176 may include two openable doors 212, including afront openable door 212 ₁ located at the front end 176 a, and a rearopenable door 212 ₂ provided to cover an open (or partially open) rearend 176 b.

The openable doors 212 may be manually openable by a user, or an openingmechanism may be provided to move doors 212 to the open position when,e.g., robot dirt bin 176 is to be emptied and/or when robotic vacuumcleaner 104 docks at the docking station 108.

Doors 212 may be openable in any manner known in the art. Severalexemplary opening mechanisms are discussed subsequently. For example,doors 212 may be pivotally openable using, for example, a rotating swingdoor design (see for example FIG. 7), a rotating axle design (see forexample, FIG. 8), or a rotating gear design (see for example FIG. 9).

The robot dirt bin 176 is also provided with a dirt inlet 188, which maybe of any design known in the robotic vacuum cleaner arts and may beprovided at any location known in the robotic vacuum cleaner arts. Asexemplified in FIG. 3, the rear end 176 b of dirt bin 176 is providedwith the dirt inlet 188 for receiving dirt and debris that is collectedby the robotic vacuum cleaner 104 during the course of cleaning. Inother cases, dirt inlet 188 can also be located at other locationsaround dirt bin 176, including on the side face 176 e of bin 176 (seefor example FIG. 4A). As exemplified in FIG. 4B, in embodiments whereinthe dirt bin 176 comprises a removable component, the robot housing 140can include a dirt inlet 232 (FIG. 4B), which is in fluid flowcommunication with into the robot dirt bin inlet 188 when bin 176 ispositioned inside of housing cavity 220.

The robotic vacuum cleaner may also be provided with any floor cleaningmember known in the robotic vacuum cleaner arts. Referring to FIGS. 3and 4, a sweeper 172 can be located on a lower end 148 of the vacuumrobot 104, and can be used for sweeping dirt and debris from surfacesduring cleaning. As exemplified, sweeper 172 can comprise one or morerotating brushes which, by itself using a mechanical sweeping action orin combination with an air flow, conveys dirt through the dirt inlet 188into the dirt bin 176.

In various embodiments, as provided in further detail herein, therobotic vacuum cleaner may also have a suction motor 180 to draw, orassist in drawing, dirt into robot dirt bin 176. In such an embodiment,sweeper 172 can also function as a dirty air inlet for the roboticvacuum cleaner 104. If a suction motor is provided, then a clean airoutlet 196 may be provided. The clean air outlet 196 may be located at alower end of the robotic vacuum cleaner 104 as exemplified in FIG. 3,but may alternately be provided at other locations around the robot body140 (e.g., top end 144 as exemplified in FIG. 4, or at a rear end 160).Accordingly, an airflow path 184 extends between the dirty air inlet (orsweeper) 172 and the clean air outlet 196 with the suction motor 180positioned in the airflow path 184 to generate a vacuum suction throughthe airflow path 184. As exemplified, suction motor 180 may bepositioned downstream of dirt bin 176, and is located inside of motorhousing 182. Suction motor 180 can be, for example, a fan-motor assemblyincluding an electric motor and impeller blade(s).

If a suction motor 180 is provided, then, as exemplified in FIGS. 3 and4, one or more pre-motor filters 204 may be provided in the airflow path184, upstream of the suction motor 180. Pre-motor filters 204 can beformed from any suitable physical, or porous filter media. For example,pre-motor filters 204 may be one or more of a foam filter, a feltfilter, a HEPA filter, or other physical filter media. In someembodiments, pre-motor filter 204 may include an electrostatic filter,or the like.

During operation of the exemplified robotic vacuum cleaner 104, suctionmotor 180 is activated (i.e., via the power switch 164 in FIG. 2) todrive airflow, through airflow path 184, such that air is drawn throughthe sweeper (i.e., dirty air inlet) 172, and into the robot dirt bin 176via inlet 188 (FIG. 3). The airflow may continue through an air outlet206 of dirt bin 176, and downstream through an air passage 192 a to thesuction motor 180. As exemplified in FIG. 4A, in some cases, anadditional pre-motor filter 204 b may be provided at outlet 206, toprevent airborne dirt from being carried downstream toward the suctionmotor 180. As exemplified in FIG. 3, air exiting the suction motor 180may continue through a second air passage 192 b, and exits the clean airoutlet 196. In various embodiments, upon de-activating the suction motor180, dirt which aggregates on the filter 204 b may collapse and collectinside dirt bin 176.

As exemplified in FIG. 4C, in embodiments wherein the dirt bin 176comprises a separately removable compartment, the compartment mayinclude an air outlet 236 which aligns with outlet 206, when the dirtbin 176 is received inside of cavity 220. Optionally, as exemplified,the air outlet 236 can include a separate filter medium 238. The filtermedium 238 can prevent dirt and debris from escaping the dirt bin 176,via outlet 236, when the dirt bin 176 is extracted for cleaning.Alternately, or in addition, air outlet 236 may have an openable doorfor closing air outlet 236.

General Description of a Docking Station

A docking station 108 may be of any shape and configuration. Referringto FIG. 1, as exemplified, the docking station 108 comprises a body (orhousing) 110 having a top end (or upper end) 116, a bottom end (or lowerend) 120, a front end 124 and a rear end 128. Body 110 also includeslateral side faces 132, which extend between the front and rear ends.Optionally, a base 136 is provided at the lower end 120 to stabilize thedocking station 108 in the upright position.

In the exemplified embodiment, the docking station 108 is generallyconfigured as a vertical, rectangular structure, having an uprightsection 112. In other cases, the docking station 108 may have any othersuitable shape or design.

As best exemplified in FIGS. 6A-6C, the docking station 108 may includean opening port 262 (also referred to herein as a dirt inlet 262),disposed at the front end 124 of the docking housing 110. The openingport 262 is positioned to be in fluid flow communication with, e.g., itmay be aligned a with and be abutted by opening port 168 of the roboticvacuum cleaner 104 when the robotic vacuum cleaner 104 is to be emptied(e.g., the robotic vacuum cleaner is docked at the docking station). Inthis configuration, the docking station 108 can receive dirt and debris,ejected from the docked robotic vacuum cleaner 104, through dirt inletport 262. In other embodiments, port 262 may be located at any othersuitable location on the docking station body 110.

Optionally, as exemplified in FIGS. 5 and 6, a sealing member 106 may beattached (e.g., permanently or removably attached) around the portopening 262, and at the front end 124 of docking station 108. Thesealing member 106 may be any member which can create a seal between theoutlet 168 of the robotic vacuum cleaner 104 and the opening or dirtinlet port 262 of the docking station 108. For example, the sealingmember 106 may comprise a rigid interface member (see for example FIGS.5A and 5B), a flexible or compressible member (e.g., a bellows or thelike) (see for example FIG. 5C) or a gasket-like member. As exemplified,upon docking the robotic vacuum cleaner 104, the sealing member 106 canengage to surround the dirt outlet port 168 of the robotic vacuumcleaner 104, and can be used to prevent dirt and debris from escapingwhen transferring dirt and debris between the robot dirt bin 176 and thedocking station 108.

Alternately, or in addition, and as explained subsequently in furtherdetail with reference to FIGS. 25-29, a connection interface 264 may beattached to a front end 124 of the docking station 108 (e.g.,integrally, or removably attached thereto). The connection interface 264can be provided in addition to, or as an alternative to, the sealingmember 106. In the exemplified embodiments, and as explained in furtherdetail herein, the connection interface 264 can be used to house a dirttransfer mechanism for transferring the contents of robot dirt bin 176into docking station 108.

As best exemplified in FIGS. 5-6, the docking station 108 can furthercomprise a dirt receptacle 248. Dirt receptacle 248 may be of any designwhich collects and retains dirt, transferred from the robotic vacuumcleaner 104 to the docking station 108. The dirt receptacle 248 may besecured in position in the docking station 108 such that it is notintended to be user removable, or it may be the docking station 108itself or it may comprise a separate removable compartment (see forexample, FIGS. 5A and 5B).

If the dirt receptacle 248 is not removable from the docking station 108or is the docking station 108 itself, then an openable door may beprovided to permit the dirt receptacle 248 to be emptied. For example,dirt receptacle 248 may have a bottom that is openable when it isremoved from the docking station. Alternately, if the dirt receptacle248 is a non-removable component of the docking station, then theportion of the docking station that houses, comprises or consists ofdirt receptacle 248 may be removable and it may have a bottom that isopenable when it is removed from the docking station.

If the dirt receptacle 248 is removable, then the docking station 108may include a cavity 250 for removably receiving the dirt receptacle 248and at least one open end 249, through which the dirt receptacle 248 maybe removed for emptying. For example, as exemplified in FIGS. 5A and 5B,the open end 249 may be the upper end 116 of the docking station 108,which may be used for accessing and removing (or replacing) thereceptacle 248. In other embodiments, the opening for removing the dirtreceptacle 248 may be provided at any other location around the dockinghousing 110.

A removable dirt receptacle 248 may be self-supporting, e.g., it maycomprise a rigid bin, or it may not be self-supporting, e.g., are-usable or disposable bag (e.g., a wax or plastic bag) in which casethe docking station 108 may support the disposable bag during a robotemptying operation.

Preferably, an openable door or lid 240 is provided to cover or seal theopen end 249 of the docking station 108 while the receptacle 248 isdisposed inside of the docking station 108. For example, lid 240 can beused to seal the open end 116 during operation and/or non-use of thedocking station 108. The lid 240 may be removable from docking station108, or it may be rotatably mounted thereto, or it may be translatableto an open position. As exemplified in FIG. 5C, the openable lid 240 ispivotally connected to the docking housing 110 by a hinge 244.Alternatively, or in addition, an openable lid can also be provided onthe receptacle 248, rather the docking station housing (notillustrated). In particular, an advantage of this design is that thereceptacle 248 can be transported (e.g., carried) to an emptyingcontainer (e.g., a larger garbage bin) while the opening 249 is covered,thereby preventing plumes of dust from forming during transport.

If the receptacle is removable or a separate component from the dockingstation housing 110, then the dirt receptacle 248 can include one ormore dirt openings 252 that are positioned to be in fluid flowcommunication with, e.g., to generally align with and abut, dirt openingport 262 of the docking station 108, when the dirt receptacle 248 isdisposed inside of the docking station 108 (see for example FIG. 6A).Accordingly, dirt can be transferred from the robot 104 into thereceptacle 248, via the dirt opening 252.

It will be appreciated that if the dirt receptacle 248 is not removablefrom the docking station 108 or is the docking station 108 itself, thenonly a single opening may be provided for connecting the dirt receptacle248 with the dirt outlet 168 of the robotic vacuum cleaner 104. Forexample, only dirt opening 262 may be provided. In such a case, opening262 may be provided with an openable door 272.

It will be appreciated that if the dirt receptacle 248 is removable fromthe docking station 108 then the dirt receptacle 248 and the dockingstation 108 may each be provided with a dirt opening 252, 262. In such acase, opening 252 and/or opening 262 may each be provided with anopenable door 254, 272.

The openable door or doors 254, 272 may be rotatable mounted,translatable or otherwise openable.

For example, as exemplified in FIG. 5B, opening 252 may be covered(e.g., sealed) by a door or flap 254. Flap 254 may cover the opening 252to prevent dirt from escaping the receptacle 248 when the receptacle isremoved from the docking station 108. Optionally, as exemplified, inorder to seal the opening 252, flap 254 may be recessed inside thereceptacle 248, and may have a cross-sectional area greater than theopening 252. As exemplified in FIG. 6, flap 254 can be opened inwardly,into the volume of the receptacle 248, to provide access into thereceptacle 248. In some embodiments, where the dirt receptacle 248comprises a rigid bin, flap 254 can comprise a rigid material (e.g., arigid door) which is pivotally attached to the receptacle 248 by a hinge256 (FIG. 5B). Flap 254 may be biased, e.g., by a spring, to the closedposition. Alternately, or in addition, the opening mechanism may secureflap 254 in the closed position.

As exemplified in FIG. 6, the docking station opening 262 may alsoinclude an openable door 272. Openable door 272 may seal the dockingstation 108 when the robotic vacuum cleaner 104 is not docked. In theexemplified embodiment, door 272 is pivotally mounted to the dockingstation housing 110 by hinge 274, and can pivot either forwardly orrearwardly.

As exemplified in FIG. 6B, door 272 can pivot rearwardly to push openthe dirt receptacle flap 254, and accordingly, allow dirt to betransferred into the dirt receptacle 248. Alternatively or in addition,as exemplified in FIG. 6C, where the flap 254 comprises a rigid door,docking station door 272 may not be necessarily provided, and receptacledoor 254 can act as a doorway for both the docking station 108 and thereceptacle 248.

Door Opening Mechanisms

The following is a discussion of a door opening mechanism, which may beused by itself or with any of the features disclosed herein. In theexemplified embodiments, the door opening mechanism can be used foropening one or more of: (i) door(s) 212 to the robotic vacuum cleanerdirt bin 176; (ii) door 272 to the docking station 108; and/or (iii) adoor 254 associated with the dirt receptacle 248, in order to allow dirtto be transferred from the robot dirt bin 176 into docking station 108during docking.

The door opening mechanism may be part of a mechanical transfer memberwhereby the door or doors are opened as the mechanical transfer membermoves to transfer dirt from the robotic surface cleaning apparatus tothe docking station. Accordingly, the door opening mechanism maycomprise a mechanical door opening mechanism which is part of a dirttransfer mechanism (see for example FIGS. 10 and 15). A mechanical dooropening mechanism may be part of a dirt transfer mechanism and mayengage and open the door as part of a dirt transfer operation.Accordingly, mechanical door opening mechanisms are discussedsubsequently.

Alternately, the door opening mechanism may be activated when themechanical transfer member or the pneumatic dirt transfer mechanism isactuated or when the robotic vacuum cleaner 104 docks at the dockingstation 108. In such an embodiment, the door opening mechanism maycomprise an electrically operated motor which is energized when themechanical transfer member or the pneumatic dirt transfer mechanism isactuated.

Similarly, the door opening mechanism may close the door(s) when thedirt transfer is completed or when the robotic vacuum cleaner leaves thedocking station 108. Alternately, or in addition, the door(s) may bebiased to a closed position.

As exemplified, the door opening mechanism may comprise an electric dooropening mechanism that is drivingly connected to the door by a linkingmechanism. As exemplified in FIGS. 7-9, the linking mechanism comprisesan axle of a drive motor that is drivingly (e.g., rotatably) connectedto the door. Alternately, the linking mechanism may be a telescopingmember that moves axially to open and close the door. Alternately, thelinking mechanism may be a drive arm similar to that shown in FIG. 13C.

FIGS. 7-9 exemplify various embodiments for an automatic electric dooropening mechanism. As exemplified, the robotic vacuum cleaner 104 isprovided with a door 212 and the docking station is also provided with adoor 272. An electric motor 276 is drivingly connected to the door tomove the door between the open and closed position. The motor 276 isactuated by a signal provided by a control unit 296. The control unit296 issues a signal in response to an actuator (an activation switchunit), which may be a manually operable switch (e.g., a user actuatesthe switch), or a sensor (e.g., a proximity sensor, an optical sensor, apressure sensor or a reed switch) that detects when the robotic vacuumcleaner docks at the docking station, or a circuit that is closed whenthe on board power supply of the robotic vacuum cleaner 104 commencesrecharging after the robotic vacuum cleaner has docked at the dockingstation 108.

As best exemplified in FIG. 7A, each door is provided with an automaticdoor opening mechanism that comprises an electric motor 276 drivinglyconnected to the door to open the door 272, 212. In particular, each ofthe robotic vacuum cleaner door 212 and the docking station door 272 isrotated by a respective electric motor 276 ₁, 276 ₂. Each motor 276 is,in turn, controlled by a control unit 296 ₁, 296 ₂, via, e.g., a cablewire 298. In various cases, control units 296 can also house powersupplies (e.g., batteries) to power the motors 276 or the motors 276 maybe powered by an on board power supply of the robotic vacuum cleaner.Each control unit 296 is electrically coupled via, e.g., a cable 292 toa respective activation switch unit 288 ₁, 288 ₂.

Activation switch units 288 operate to transmit activation signals tocontrol units 296 upon, e.g., docking of robotic vacuum cleaner 104 atthe docking station 108 and/or the robotic vacuum cleaner leaving thedocking station 108. Upon receiving the activation signal, the controlunits 296 can control the opening and/or closing of doors 212, 272, viamotors 276. In the exemplified embodiments, the activation switch unit288 ₁ for the robotic vacuum cleaner is provided at a front end 156 ofthe robot housing 140, while the activation switch unit 288 ₂ for thedocking station 108 is provided at a front end 124 of the dockingstation housing 110.

Activation units 288 can comprise any suitable switch mechanism known inthe art. In the exemplified embodiment of FIG. 7, activation units 288each comprise a pressure sensor, which is configured to transmit anactivation signal upon sensing applied pressure. As exemplified in FIG.7B, the pressure sensors 288 are each positioned—on the robotic vacuumcleaner and docking station housings—to directly engage (e.g., contact)each other upon docking of the robotic vacuum cleaner 104. Uponcontacting, each pressure sensor 288 may transmit an activation signalto a respective control unit 296, to activate motors 276 and open doors212, 272. In this manner, the pressure sensors 288 facilitate automaticopening of doors 212, 272 upon docking robotic vacuum cleaner 104. Inother embodiments, pressure sensors 288 may not directly engage eachother at docking, but rather, may engage reciprocal surfaces of thedocking station 108, robotic vacuum cleaner 104 and/or sealing member106 and maybe located at different locations.

It will be appreciated that, in an alternate embodiment, a single motormay be driving connected to each door 212,272.

FIGS. 8 and 9 exemplify an alternative embodiment for activation units288. In the exemplified embodiments, activation units 288 each comprisea reed switch, that is opened and closed by an applied magnetic field.As exemplified, magnets 320 are positioned at a front end 124 of dockingstation 108, and at a front end 156 of the robotic vacuum cleaner 104.During docking of the robotic vacuum cleaner 104, reed switches 288engage complementary magnets 320 provided on a reciprocal surface of therobotic vacuum cleaner 104 and docking station 108. Each magnet 320operates to “close” the reed switch 360, and in turn, complete a circuitdefined by the control unit 296, and forward and return wires 292 a, 292b. The closing of the circuit, in turn, causes each control unit 296 toactivate a motor 276, and automatically open respective doors 212, 272.

In other cases, the activation switch unit 288 can be manually activatedby the user, and can comprise, for example, a button, a switch, or thelike, provided on an exterior of the robot and/or docking stationhousings.

In the embodiments exemplified in FIGS. 7-9, upon receiving anactivation signal from activation switch units 288, motors 276 canoperate to open the doors 212, 272. Similarly, when the robotic vacuumcleaner leaves the docking station 108 and/or when a transfer operationis complete, activation switch units 288 may issue a signal to themotors whereby the motors close the doors.

FIG. 7A-7C exemplify a first door opening configuration using rotatable“V”-shaped doors wherein the drive motor is indirectly driving connectedto the door. As exemplified, the robot dirt bin door 212 may comprise afirst “upper” portion 212 a joined to a second “lower” portion 212 b,forming a “V”-shaped member. Portions 212 a, 212 b can be joinedtogether by a hollow cylinder 282, which receives a rod 286. Door 212 isrotatable about rod 286, e.g., by one or more bearings. Rod 286 isattached, optionally non-rotatably mounted at opposite axial ends 286 a,286 b, to the robot housing 140. In this configuration, door 212 isrotatable between the closed position (FIG. 7A) and an open position(FIG. 7B) about a rotation axis 224 defined by the axis of extension ofrod 286.

As best exemplified in FIG. 7A, hollow cylinder 282 and rod 286 may bepositioned at a top-forward end, of dirt bin 176 (i.e., the interfacebetween dirt bin 176 and the robot housing 140). In this arrangement,the upper door portion 212 a is disposed above the dirt bin 176, whilethe lower door portion 212 b is disposed to cover the open front end 176a of dirt bin 176.

To pivot door 212 between the open and closed positions, a cord 280 ₁(e.g., cable or other intermediary member) is attached at a first cableend 280 a ₁ to the upper door portion 212 a (FIG. 7C). The cordindirectly connects the motor to the door. The second cable end 280 b ₁is attached to (e.g., wound around) a spool 284 ₁. Spool 284 ₁, in turn,is drivingly connected to the spool motor 276 ₁. As exemplified, spoolmotor 276 ₁ is located above the robotic dirt bin 176, and rear of thedoor 212. In this configuration, spool motor 276 ₁ can be used to windor unwind the cord 280 ₁, in order to open the door 212 (FIG. 7B), orotherwise, release the door 212 back into the closed position (FIG. 7A).Optionally, door 212 is biased to the closed position by, e.g., atorsion spring, such that, when spool motor 276 ₁ unwinds the cable, thedoor will move to the closed position.

The docking station door 272 may also have a similar door configuration,comprising an upper door portion 272 a and a lower door portion 272 bjoined together to form a “V”-shaped member. A cable 280 ₂ connects theupper portion 272 a to spool 284 ₂, which is wound or unwound by spoolmotor 276 ₂. An optional torsion spring may also be provided.

Optionally, each door may have a heavier lower door portion 212 b, 272 bthan the upper door portion 212 a, 272 a. An advantage of this design isthat the heavier lower portion 212 b, 272 b may assist in pivoting thedoor into the closed position, once cords 280 are un-wound by motors 276(i.e., under the force of gravity).

FIGS. 8A-8B exemplify an alternative door opening configuration whereinthe motor is directly connected to the door (e.g., the drive axle of themotor is drivingly connected to the door). As best exemplified in FIG.8B, robot dirt bin door 212 may comprise a longitudinally extendingmember 282, attached to a lateral edge of the door 212. Member 282 canextend between a first lateral end 282 a and an axially opposed secondlateral end 282 b. As exemplified, the first end 282 a is non-rotatablymounted to rotating axle 322 of motor 276. The motor 276 and axle 322can be jointly positioned at the interface between the top of the dirtbin 176 c, and the housing 140, and at a forward-end 176 a of the dirtbin 176 (FIG. 8A). In this configuration, motor 276 rotates axle 322 topivot the door 212, about rotation axis 224, between the open and closedpositions. A similar configuration can be applied with respect to door272 of the docking station 108.

FIGS. 9A-9B exemplify still a further alternative door openingconfiguration wherein the motor is indirectly drivingly connected to thedoor by intermediary members comprising gears. In this embodiment, themotor drives a drive gear 334 b and a mating driven gear 334 a isprovided on the door. As exemplified in FIG. 9B, the longitudinallyextending member 282 of door 212 is connected, at a first lateral end282 a, to a first rotating toothed gear 334 a. In the exemplifiedembodiment, the gear 334 a is non-rotationally mounted to thelongitudinally extending member 282. The first gear 334 a is, in turn,in toothed engagement with a second rotating gear 334 b. As exemplified,second gear 334 b is non-rotationally mounted to an axle 322 of motor276. Each of the second gear 334 b and the motor 276 can be disposedabove the dirt bin 176. In this configuration, upon activation of motor276, the drive gear 334 b may rotate to turn the driven gear 334 a and,in turn, pivot the door 212, about rotation axis 224, into the openposition. Similarly, the motor may be rotated in the reverse directionto close the door. A similar configuration can be used with respect ofdocking station door 272, using interleaved gears 336 a, 336 b.

While the embodiments in FIGS. 7-9 exemplify various electrical dooropening mechanisms, in other embodiments, the door opening mechanism canalso comprise a mechanical door opening mechanism using, for example, amechanical ram. These embodiments will be described in further detailherein, with reference to FIGS. 10-15.

Dirt Transfer Mechanism

The following is a discussion of a dirt transfer mechanism which is usedfor cleaning (e.g., removing) dirt and debris from the robot dirt bin176. The dirt transfer mechanism can be used by itself, or with any ofthe features previously disclosed herein, including the door openingmechanism. In the exemplified embodiments, the dirt transfer mechanismmay comprise one or more of: (a) a mechanical dirt transfer mechanism;and/or (b) a pneumatic dirt transfer mechanism.

(a) Mechanical Dirt Transfer Mechanism

A mechanical dirt transfer mechanism comprises a member (e.g., amechanical transfer member) which physically engages and moves dirt fromthe robot dirt bin 176 towards or into the docking station 108 (dirtreceptacle 248). The mechanical dirt transfer member may push the dirtout of the robot dirt bin 176 towards or into the docking station 108and/or may pull the dirt out of the robot dirt bin 176 towards or intothe docking station 108. As such, the mechanical dirt transfer mechanismmay travel through part or all of the robot dirt bin 176 (e.g., it maysweep across all or part of the floor of the robot dirt bin 176).

As exemplified, the mechanical dirt transfer mechanism may be locatedinside one or more of the robotic vacuum cleaner 104 (see for exampleFIGS. 10-14), and/or the docking station 108 (see for example FIGS.15-16).

As exemplified in FIGS. 10-14 and FIGS. 15-16, the mechanical dirttransfer member 344 may comprises a sweeping portion 344 a that islongitudinally translatable through at least a portion of the robot dirtbin 176 In particular, as the sweeping portion 344 a is translatedinside all or part of the robot dirt bin 176, the sweeping portion 344 ais configured to engage dirt in the robot dirt bin 176 and push (FIGS.10-14) and/or pull (FIGS. 15-16) the dirt through and, optionally, outof the robot dirt bin 176 and into the dirt receptacle 248 of thedocking station 108.

Sweeping portion 344 a may have a cross-sectional area in a planetransverse to the longitudinal axis 138 that is proximate (e.g.,slightly smaller than) the cross-sectional area of the robot dirt bin inthe plane transverse to the longitudinal axis 138. Accordingly, assweeping portion 344 a is translated longitudinally through robot dirtbin 176, sweeping portion 344 a pushes or pulls dirt through andoptionally out of the robot dirt bin 176.

In the exemplified embodiments of FIGS. 10-14, sweeping portion 344 a oftransfer member 344 is configured as a planar member having across-sectional area that is substantially equal to the cross-sectionalarea of the robot dirt bin 176. In other embodiments, sweeping portion344 a may have any other suitable design, shape or configuration. Forexample, as exemplified in FIGS. 15-16 and as provided in further detailherein, sweeping portion 344 a may be configured as a foldable sweepingportion 344 a which includes a pivoting first sweeping member 344 a ₁and second sweeping member 344 a 2.

Optionally, the sweeping portion 344 a may engage one or more of thelateral sidewalls of the robot dirt bin 176 (e.g., the sweeping portion344 a may have a lower end that sweeps along the floor of the robot dirtbin 176 as the sweeping portion travels e.g., from a rear end of therobot dirt bin 176 to the front end of the robot dirt bin 176).Accordingly, one or more of the lateral sides, the upper side and thelower side of the sweeping portion that face a lateral sidewall, theupper wall and/or the floor of the robot dirt bin 176 may have brushmembers, rubber wipers or the like that travel along or proximate thelateral sidewalls, the upper wall and the floor of the robot dirt bin176 to move dirt through the robot dirt bin 176.

Optionally, as exemplified in FIG. 11, at least a portion of alongitudinal edge of the sweeping member 344 a that is directed towardthe top surface 176 c of the dirt bin 176 is lined with one or morescraping members 194 (i.e., scraping teeth) (FIG. 11D). As exemplifiedin FIGS. 11B and 11C, scraping members 194 can scrap (e.g., debride) agrill 198 for filtering large particles, which covers the air outlet 206that leads to the air passage 192 a, as the transfer member 344 istranslated between the storage and emptied positions. In other cases thegrill 198 may not be provided, and the scraping members 194 may directlyengage a pre-motor filter 204 a covering the air outlet 206.

Sweeping portion 344 a may be translatable axially through the robotdirt bin 176 between a storage or floor cleaning position (FIGS. 10A,11A, 12A, 13A, 14A, 15A), and one or more dirt emptying position (FIGS.10B-10C, 11B—11C, 12B, 13B, 14B, 15B—15D). FIGS. 10-15 exemplifyembodiments where the mechanical transfer member 344 is provided insidethe robotic vacuum cleaner. As exemplified, in FIGS. 10A, 11A, 12A, 13Aand 14A, in the floor cleaning position, the sweeping portion 344 a maybe positioned such as to not obstruct the flow of air through the dirtbin 176 in a floor cleaning mode. For instance, as exemplified in FIGS.10A, 11A, 12A, 13A and 14A, in the floor cleaning position, the sweepingportion 344 a may be optionally recessed behind the rear end 176 b ofthe robot dirt bin 176 and inside a cavity 356 located rearward andexterior to the robot dirt bin 176. In other embodiments, in the floorcleaning mode, the sweeping portion 344 a may be provided inside therobot dirt bin 176, and recessed proximal the rear end 176 b.

FIG. 15A exemplifies an alternative embodiment where the mechanicaltransfer member 344 is located inside the docking station 108. In thisexemplified embodiment, in the floor cleaning or storage position, thesweeping portion 344 a may be disposed inside the docking station 108.In particular, as discussed subsequently herein, the docking station 108may include two compartments, a first compartment 108 a for containingthe dirt receptacle 248, and a second compartment 108 b for housing themechanical dirt transfer mechanism 344. The sweeping portion 344 a maybe located inside the second compartment 108 b in the floor cleaning orstorage position.

In the dirty emptying positions (FIGS. 10B-10C, 11B—11C, 12B, 13B, 14B,15B—15D), sweeping portion 344 a may be translated along axis 138 topush dirt out of the robot dirt bin 176 (FIGS. 10B-10C, 11B—11C, 12B,13B, 14B) or pull dirt out of the dirt bin 176 (FIGS. 15B-15D) throughand, optionally, out of the dirt bin 176. In embodiments where the dirttransfer member 344 is located inside the robotic vacuum cleaner 104(FIGS. 10B—10C, 11B—11C, 12B, 13B, 14B), in the dirty empting position,the sweeping portion 344 a may be translated—along axis 138—along aportion of the dirt bin 176 and toward the front end 176 a of the dirtbin 176 and/or optionally through the dirt outlet 168 and into thedocking station 108. In embodiments where the transfer member 344 islocated inside of the docking station 108, in the dirt emptyingpositions, the sweeping portion 344 a may be translated, along axis 138,through the front end 176 a of the dirt bin 176 and at least partiallytoward the rear end of the dirt bin 176 b (FIGS. 15B and 15C) or all theway to the rear end, and back toward the docking station 108 (FIGS. 15Dand 15E).

Sweeping portion 344 a may have a drive member 344 b that moves thesweeping member longitudinally between the floor cleaning or storagepositions and one or more dirt emptying positions. The drive member 344b may push the sweeping member 344 a through the robot dirt bin (see forexample transfer member 344 of FIGS. 10-14) or may pull a sweepingmember 344 a through the robot dirt bin 176 (see for example FIGS.15A-15E, and 16A and 16B). If the drive member 344 b pulls the dirtthrough the robot dirt bin 176, then the drive member 344 b may belocated in the docking station 108 or the connection interface 246.

The drive member 344 b may be a rigid member that is pushed through therobot dirt bin, such as ram stem portion 344 b of FIGS. 10-14 or pulledthrough the robot dirt bin (see for example FIGS. 15A-15E), or may be atelescoping member that telescopes axially (in the direction of axis138) to move the sweeping member 334 a, a drive arm similar to thatshown in FIG. 13C, an inflatable member that inflates rearward ofsweeping portion 344 a to push sweeping portion 344 a or the like.

Each portion of transfer member 344 may be formed of any suitablematerial, including a rigid material or a flexible material. In somecases, the sweeping portion 344 a and stem portion 344 b may be eachformed from different materials. An advantage of forming sweepingportion 344 a and/or stem portion 344 b from flexible material is that,the transfer member 344 may be deployed in areas having non-linearcontours. For example, if the cavity in which drive member 344 b islocated is non-linear, then it may be beneficial for the drive member344 b to be made of a flexible material. For instance, as exemplified inFIG. 3, the robot dirt bin 176 may have a curvature, which requiressweeping portion 344 a and/or stem 344 b to be sufficiently flexible tobend with the curvature as ram 344 translates through the robot dirt bin176.

Referring now to FIGS. 10-14 which exemplify a case where the mechanicaltransfer member 344 is located inside the robotic vacuum cleaner 104. Inthe exemplified embodiment, the mechanical dirt transfer mechanisms maybe configured as a “ram” like member wherein the drive member 344 bcomprises a longitudinal stem portion 344 b. As exemplified, stemportion 344 b extends axially, along axis 138, between a first stem end344 b ₁ and a second stem end 344 b 2. In the exemplified embodiment,the first end 344 b ₁ is mounted to the rear side of sweeping portion344 a. (Stem portion 344 b extends through the rear wall of robot dirtbin 176.)

Stem portion 344 b is slidably moveably mounted in the robotic vacuumcleaner 104 and extends along axis 138. For instance, as exemplified inFIG. 11, the stem portion 344 b may be positioned rearwardly andexterior of robot dirt bin 176, such as in cavity 356 of the robothousing. The rear end 176 b of the robot dirt bin 176 may comprise anopening to allow the stem portion 344 b to translate the sweepingportion 344 a through the robot dirt bin 176 (also referred to herein asa mechanical transfer member inlet port 183, exemplified in FIGS.11A-11C). In this manner, stem portion 344 b may extend through theopening port 183 in the rear wall 176 b of robot dirt bin 176 to pushthe sweeping portion 344 a through the robot dirt bin 176. In thisconfiguration, axial sliding of stem portion 344 b, inside of cavity356, controls and stabilizes axial motion of the sweeping portion 344 ainside the dirt bin 176. It will be appreciated that stem portion 344 bmay have any suitable axial length to extend sweeping portion 344 a tovarious emptied positions. For example, as exemplified in FIG. 11A, stem344 b may have an axial length 342, which is defined between the firststem end 344 b ₁ and the second stem end 344 b 2, that is substantiallyequal to, or greater, than the axial length 178 of dirt bin 176, i.e.,defined between the front end 176 a and the rear end 176 b of dirt bin176. An advantage of this configuration is that the sweeping portion 344a may translate across the entire axial length of the dirt bin 176, soas to transfer dirt completely out of the bin 176. As exemplified inFIG. 10C, in other cases, the axial length of the stem portion 344 b canbe greater than the dirt bin 176. An advantage of this design is thatsweeping portion 344 a may extend to further transfer dirt into thedocking station 108 when the robotic vacuum cleaner 104 is in the dockedposition. Accordingly, stem portion 344 b may have a length to extendthrough interface 246 (if provided) and into dirt receptacle 248. Thecavity 356 may have an axial length which is at least as equal to theaxial length of stem 344 b, so as to receive the stem 344 b in thestorage position. It will be appreciated that the stem portions may be atelescoping member.

In addition to ejecting dirt and debris from the dirt bin 176, stemportion 344 b can also be used as a mechanical door opening mechanismfor opening one or more of the robot dirt bin doors 212 ₁ and 212 ₂,docking station door 272 and/or a dirt receptacle door 254. For example,as exemplified in FIGS. 10B and 10C, as the ram 344 is translated intothe emptied position, the sweeping portion 344 a may engage, and causethe doors 212 and 272 to pivot open.

Preferably, as exemplified in FIG. 10, the stem portion 344 b maycomprise a flange member, which can be used to hold (e.g., prop) thedoors in the open position as the sweeping member 344 a passes by thedoor. In this manner, the flange member prevents the doors from movingtowards the closed position, behind the sweeping portion 344 a.Accordingly, the doors are prevented from engaging the sweeping portion344 a, when the sweeping portion 344 a is retracted back into thestorage position and thereby preventing the sweeping portion 344 a tomove to the storage position. As exemplified in FIG. 10, the uppersurface of the stem portion 344 b extends axially rearwardly from theupper end of the sweeping portion 344 a. Therefore, the flange member isthe upper surface of stem portion 344 b. It will be appreciated thatflange portion may be any member which will maintain a door above theupper end of the sweeping portion 344 a such that the sweeping portion344 a may be retracted to the storage position.

Optionally, as also exemplified in FIG. 10, one or more biasing memberssuch as springs 372 a, 372 b, 372 c, 372 d may be provided to bias oneor more of doors 212 ₁, 272, 254 and 212 ₂, respectively, to the closedposition. For example, as exemplified in FIG. 10A, a spring 372 a mayconnect between the front robot dirt bin door 212 ₁ and the robothousing 140, and a spring 372 d may connect between the rear robot dirtbin door 212 ₂ and the robot housing 140. Similarly, as exemplified inFIG. 10B, a spring 372 b may also connect between the docking stationhousing 110 and the door 272. Optionally, a spring 372 c may furtherconnect between dirt receptacle 248 and the receptacle door/flap 254.Each of springs 372 can be a torsion spring that is compressed when thedoors 212, 254, 272 are rotated into the open position by the ram 344.The springs 372 can then expand to automatically close the doors 212,272, as the ram 344 is retracted back into the storage position.

In other embodiments, rather than using biased springs, hinges 216 and274, for the robotic vacuum cleaner doors 212 and docking station door272, respectively, can comprise spring hinges, which bias the doors intothe closed position. Similarly, a hinge 256 for a dirt receptacle door254 (FIG. 5B) may also be configured as a spring hinge.

In the embodiments exemplified in FIG. 10-14, wherein the transfermember 344 is located inside the robotic vacuum cleaner 104, thetransfer member 344 may be translated between the floor cleaningposition and the dirt emptying positions, in any suitable manner knownin the art. In the exemplified embodiments, movement of the transfermember 344 i from the floor cleaning position to the dirt emptyingposition is actuated using one or more of an automatic electricalactivation mechanism (FIGS. 10-11), a user actuated electro-mechanicalactivation mechanism (FIG. 12), a mechanical activation mechanism (FIG.13) and/or a hydraulic or pneumatic activation mechanism (FIG. 14).

As exemplified in FIGS. 10 and 11, an automatic electrical activationmechanism is used to commence a cleaning cycle whereby the transfermember 344 is translated between the floor cleaning and dirty emptyingpositions. In this embodiment, the automatic electrical activationmechanism comprises control unit 350 which is operably connected toelectric motor 352 and an activation switch, such as activation switchunit 360, wherein upon the activation switch being actuated, such as bythe robotic surface cleaning apparatus docking at a docking station, asignal is sent to the control unit 350 which then actuates the electricmotor 352 thereby commencing an emptying cycle.

In the exemplified embodiments, and as best exemplified in FIG. 11, amechanical transfer member is actuated by an electrical activationmechanism. In this embodiment, transfer member 344 is translated betweenthe floor cleaning and dirt emptying positions using a rack and pinionsystem driven by an electric motor 352. As exemplified, the electricmotor 352 rotates a toothed gear 348 that is non-rotatably mounted to amotor shaft 352 a. The toothed gear 348 engages complimentary teeth 346,extending axially along at least a portion of the upper end of the ramstem 344 b (FIGS. 10A and 11D). In this configuration, rotating gear 348drives ram stem 344 b axially in a manner analogous to a rack-and-pinionsystem. For example, in the exemplified embodiment, gear 348 is rotatedin a clockwise direction to translate ram 344 to an emptied position.Gear 348 is then rotated in a counter-clockwise direction to reversetranslation of ram 344 back to the storage position.

As exemplified in FIG. 10, motor 352 may be in communication with acontrol unit 350, via e.g., wire 365. Control unit 350 can control motor352 in order to rotate gear 348 in a clockwise or counter-clockwisedirection. In some embodiments, control unit 350 can be the same as thecontrol unit 296 ₁, exemplified in FIGS. 7-9, used for controlling theautomated opening of the robot dirt bin door 212. In this manner, asingle control unit can be used for both automatically opening therobotic vacuum cleaner door, and translating the ram 344 into an emptiedposition, i.e., upon docking the robotic vacuum cleaner 104. In variouscases, control unit 350 can also house a power supply (e.g., batteries)to power the motor 352.

In some cases, control unit 350 can also control the number of rotationsof gear 348 by motor 352. For example, control unit 350 can controlmotor 352 to rotate gear 348 a pre-determined number of rotations in theclockwise or counter-clockwise directions. In particular, this can bedone to prevent ram 344 from over-extending in the emptied position(i.e., due to over-rotation of gear 348), and otherwise displacing stem344 b from cavity 356. Control unit 350 can also control the number ofrotations of gear 348 to ensure that the ram 344 is properly returned tothe storage position.

Electric motor 352 may be powered by the onboard energy storage memberof the robotic vacuum cleaner 104.

As exemplified in FIG. 10, electric motor 352 may be automaticallyelectrically activated to translate ram 344 into the emptied position.Accordingly, upon a robotic vacuum cleaner docking at a docking station108, a signal may be issued by a sensor which actuates the electricmotor 352 to commence an emptying cycle of the robot dirt bin 176. Forexample, control unit 350 may automatically activate the electric motor352 upon the robotic vacuum cleaner 104 docking at the docking station108.

As exemplified in FIGS. 10B and 10C, control unit 350 is connected,e.g., via one or more wires 364, to an activation switch unit 360.Activation switch unit 360 can comprise any suitable switch mechanismknown in the art and may be any of those discussed with reference toactivation unit 288 and, optionally, may be activation unit 288. Forinstance, as exemplified in FIG. 10, activation unit 360 can comprise areed switch disposed at a front end 156 of the robot housing 140. Upondocking the robotic vacuum cleaner 104, the reed switch 360 engages amagnet 368 disposed on a front end 124 of the docking station 108.Magnet 368 can also be disposed on a front end of the sealing member106, or at a front end of a connection interface 264 disposed betweenthe docking station 108 and the vacuum 104.

As exemplified, magnet 368 operates to “close” the reed switch 360, andcomplete a circuit defined by the control unit 350 and forward andreturn wires 364 a, 364 b. The closing of the circuit, in turn, causescontrol unit 350 to activate motor 352 and translate the ram 344 intothe emptied position.

In some cases, control unit 350 can automatically return the ram 344back into the storage position once the unit detects that the reedswitch 360 is reopened (e.g., the robot has undocked). In other cases,the control unit 350 can return the ram 344 back into the storageposition, immediately or shortly after, the ram 344 is translated intothe emptied position, i.e., without first waiting for the robotic vacuumcleaner 104 to undock, e.g., using a timer.

In other embodiments, activation unit 360 can comprise a pressuresensor, rather than a reed switch. Upon engaging the pressure sensor 360with a surface of the docking station 108, sealing member 106 and/or aconnection interface 264, the pressure sensor 360 may be activated totransmit a signal to the control unit 350, via, e.g., wire 364. Controlunit 350 may, in turn, activate the motor 352 to translate the ram 344into the emptied position. Accordingly, the pressure sensor can also beused to automatically activate motor 352 upon docking the robotic vacuumcleaner 104 at the docking station 108.

In some cases, the activation unit 360 can be the same as activationunit 288 (FIGS. 7-11), used for controlling opening of the dirt bin door212. Accordingly, a single activation unit can be used to controlopening of the dirt bin door 212, and translating ram 344 into the dirtemptying position.

While the use of wires has been discussed herein for issuing activationsignals, it will be appreciated that signals may be sent otherwise, suchas by using Bluetooth™.

Alternately, the electric motor may be electro-mechanically activated.Accordingly, the electric motor 352 may be actuated to commence a dirtemptying cycle of the robot dirt bin 176 upon a user actuating a switch,such as a foot pedal (see for example FIG. 12). Generally, theembodiment exemplified in FIG. 12 operates analogous to the embodimentof FIG. 10, with the exception that the activation unit 360 is activatedmechanically by a user, rather than being automatically activated upondocking the robot 104. According to this embodiment, theelectro-mechanical activation mechanism comprises control unit 350 whichis operably connected to electric motor 352 and a manually operatedactivation switch, such as foot pedal 384 or wirelessly via a smartphone, wherein upon the activation switch being actuated, such as by theuser stepping on foot pedal 384, a signal is sent to the control unit350 which then actuates the electric motor 352 thereby commencing anemptying cycle.

In the exemplified embodiment, a foot pedal 384 is rotatably mounted tothe rear end 160 of the vacuum body 140, via a rotating cylinder 404(FIG. 12C). Rotating cylinder 404 can rotate about an axis 139,transverse to longitudinal axis 138, in order to rotate foot pedal 384between an initial undepressed storage position (FIG. 12A), and adepressed emptied position (FIG. 12B).

As exemplified in FIGS. 12A and 12B, foot pedal 384 may be drivinglyconnected to an engagement member 388, via one or more linkage beams 396a, 396 b. Linkage beams 396 each comprise a first end 396 ₁, attached tothe rotating cylinder 404, and an opposed second end 396 ₂, attached toa respective engagement member 388.

As exemplified in FIG. 12A, when the foot pedal 384 is located in theinitial undepressed position, the engagement members 388 are disposedbelow, and spaced away from, activation unit 360, assuming the roboticvacuum cleaner 104 is in the upright position. Engagement members 388may move a physical switch (e.g., a push button) that causes the controlunit to issue a signal, or it may be part of a sensor system (e.g., aproximity sensor or a pressure sensor) that causes the control unit toissue a signal.

As exemplified in FIG. 12B, upon depressing the foot pedal 384downwardly (i.e., by the user's foot), cylinder 404 is rotatedclockwise, and linkage beams 396 are driven upwardly so as to cause atleast one of the engagement members 388 to contact activation unit 360.Upon contact, activation unit 360 transmits an activation signal tocontrol unit 350, to cause the unit 350 to translate ram 344 between thestorage and emptied positions, as previously described. The activationunit 360 may be de-activated by returning the foot pedal 384 back to theundepressed position and/or by a timer.

In cases where the activation unit 360 comprises a reed switch, theengagement member 388 may comprise a magnet operable to close the reedswitch 360 upon contact. In other cases, where the activation unit 360comprises a pressure sensor, the engagement member can comprise anymaterial that can be used to apply pressure to activate the pressuresensor 360.

Optionally, as exemplified in FIGS. 12A and 12B, a spring 408 isprovided for automatically returning the foot pedal 384 back to theinitial undepressed position. In the exemplified embodiment, spring 408is connected between the foot pedal 384, and a laterally portion 412 ofhousing 140, located above the foot pedal 384. A tension spring or acompression spring may be used. Other biasing members which bias thefoot pedal to the storage position may be used.

As exemplified, the compression spring 408 may expand as the userdepresses the foot pedal 384. Once pressure is relieved from the footpedal 384, the compression spring 408 can automatically retract toreturn the foot pedal 384 back to the undepressed position.

In other embodiments, the activation unit 360 can simply comprise abutton, a switch or the like, which is located on an exterior to therobot body 140. The button or switch 360 can be mechanically activated,by a user, to translate the ram 344 between the storage and emptiedposition.

In a further alternate embodiment, control unit 350 may be wirelesslyactivated by a signal issued by, e.g., a smart phone or the dockingstation. Accordingly, when the robotic vacuum cleaner 104 docks thedocking station may issue a signal which is received by the control unit350 and thereby actuates an emptying cycle.

In the embodiment of FIG. 12, sweeping member 344 a may be moveable intothe docking station as far as is exemplified in FIG. 10C, or further.

FIG. 13 exemplifies an alternative configuration, wherein the ram 344 istranslated between the storage and emptied position using only amechanical activation mechanism. In this embodiment, the mechanicalactivation mechanism comprises a manually operated activation switch,such as foot pedal 384, wherein upon the activation switch beingactuated, such as by the user stepping on foot pedal 384, an emptyingcycle is operated.

In the exemplified embodiment, foot pedal 384 is drivingly engaged tothe ram 344, by a linkage system 396. As exemplified, linkage system 396comprises three connected linkage beams 396 a, 396 b, 396 c. Eachlinkage beam extends between a respective first end 396 a ₁, 396 b ₁,396 c ₁ and a respective second end 396 a ₂, 396 b ₂, 396 c ₂. It willbe appreciated that, in other embodiments, the linkage system 396 maycomprise any other number of connected linkage beams.

As exemplified, first linkage 396 a may have a first end 396 a ₁ whichis pivotally connected to the rotating disk 404, and a second 396 a ₂connected to the second linkage 396 b (i.e., a first end 396 b ₁ of thesecond linkage 396 b). Second linkage 396 b is, in turn, connectedbetween the first and third linkages 396 a, 396 c. Third linkage 396 cis pivotally connected—at a first end 396 c ₁—to the second linkage 396b (i.e., a second end 396 b ₂ of the second linkage), and is pivotallyconnected—at a second end 396 c ₂—to a portion of ram 344. In theexemplified embodiment, the third linkage 396 c can connect to the ram344 through an axial slot opening 357 extending into the housing cavity356. As exemplified, in the storage or floor cleaning position (FIG.13A), third linkage 396 c is angled below the second linkage 396 b.

In order to drive ram 344 into the dirt emptying position (FIG. 13B),foot pedal 384 is depressed downwardly to rotate disk 404 in a clockwisedirection. This, in turn, drives upwardly the first linkage 396 a, andfurther causes the second linkage 396 b to rotate upwardly, andrearwardly. As the second linkage 396 b is driven upwardly andrearwardly, the second linkage 396 b pivots away from the third linkage396 c, allowing the third linkage 396 c to translate ram 344 into theemptied position. To return the ram 344 back into the storage position,the foot pedal 384 is returned to the initial undepressed state, whichcauses the linkage system 396 to retract ram 344 back into the storageposition.

Preferably, a first biased spring 408 a is provided between the secondand third linkages 396 b, 396 c. Spring 408 a is biased in the expandedstate, and expands to assist the third linkage 396 c to rotate (e.g.,pivot) away from the second linkage 396 b, and in turn, translate ram344 into the emptied position.

Optionally, a second biased spring 408 b is located below the foot pedal384, and is used to automatically return the foot pedal 384 back to theundepressed position. As exemplified, the spring 408 b can connectbetween pedal 384 and a laterally extending portion 412 of the robothousing 140, disposed below the pedal 384. The spring 408 b iscompressed as the foot pedal 384 is depressed, and automatically expandsas pressure from the foot pedal 384 is relieved. Accordingly, spring 408b automatically drives the foot pedal 384 into the initial undepressedposition, and causes the linkage system 396 to automatically retract ram344 back into the storage position.

Preferably, where both springs 408 a and 408 b are provided, the springfactor of spring 408 b may be greater than the spring factor of spring408 a. In this manner, the expansive force of spring 408 a does notoverwhelm spring 408 b, thereby inadvertently translating the ram 344from the storage position to the cleaned position while the foot pedal384 is not depressed.

While FIGS. 12 and 13 exemplify a foot pedal used in conjunction with anelectro-mechanical, or mechanical activation mechanism, it will beappreciated that any other user-actuatable mechanical mechanism can beused in place of a foot pedal and the exemplified driving mechanism soas to drive motion of the ram 344. For example, in some cases, anadjustable lever can be provided in place of the foot pedal 384.

FIG. 14 exemplifies a further alternative embodiment wherein the ram 344is translated between the storage and emptied positions using ahydraulic or pneumatic activation mechanism. In this embodiment, thehydraulic or pneumatic activation mechanism comprises a container (e.g.,a cylinder) which comprises a fluid (which may be a compressed gas)wherein the fluid drives a mechanical member (e.g., ram 344) upon anactivation switch being actuated (such as by the robotic surfacecleaning apparatus docking at a docking station), thereby commencing anemptying cycle. The fluid may be pressurized in which case theactivation switch may open a valve enabling the compressed fluid todrive, e.g., a ram 344. Alternately, the docking of the robotic surfacecleaning apparatus docking at a docking station may drive the fluid tothereby drive, e.g., the ram 344. As exemplified in FIG. 14A, ram stem344 b is slidably received inside of a cavity formed by cylinder 356 a.Cylinder 356 a extends between a first open end 356 a ₁, and an axiallyopposed second open end 356 a ₂. The second end 356 a ₂ is fluidicallycoupled, via a connecting tube 356 b, to a piston cylinder 356 c.

Piston cylinder 356 c also extends, along an axis parallel to axis 138,between a first and second open end 356 c ₁, 356 c ₂, respectively. Asexemplified, the first open end 356 c ₁ is located at a front end 156 ofthe robot housing, and slidably receives a piston 416. The second openend 356 c ₂ is connected to the tube 356 b. The piston 416 includes aplanar piston portion 416 a sized to fit inside of the piston cylinder356 c, and an axially extending piston rod 416 b, which in the floorcleaning or storage position, may at least partially protrude from anopening 419 located at the front end 156 of the robotic vacuum housing140.

The connected system 356 may be filled with pressurized gas (e.g., apneumatic system), or a pressurized fluid (e.g., a hydraulic system).

In the storage or floor cleaning position (FIG. 14A), ram stem 344 b is,at least partially, disposed inside of cylinder 356 a, while the pistonrod 416 b is, at least partially, disposed outside of piston cylinder356 c. Further, the planar piston portion 416 a is recessed toward thesecond end 356 c ₂ of the piston cylinder 356 c. As exemplified in FIG.14B, upon docking the robot 104, an axial end of the piston rod 416 bengages a wall of the docking station 108, sealing member 106 and/or aconnection interface 264, and axially translates the piston planarportion 416 a across at least a portion of the axial length of thepiston cylinder 356 c toward the first piston cylinder end 356 c ₁.This, in turn, generates a build-up of positive pressure in theconnected system 356, and causes the pressurized medium to flow throughtube 356 b, and eject ram stem 344 b out of cylinder 356 a.

To retract the ram 344 back to the floor cleaning or storage position, auser may extract the piston rod 416 b such as to translate the pistonplanar portion 416 a back toward the second cylinder end 356 c ₂. Forexample, a user can extract the piston rod 416 b after undocking therobot 104. In particular, extracting the piston 416 results in a buildupof negative pressure in the connected system 356, and in turn, causesthe ram stem 344 b to retract back into the cylinder 356 a.

Optionally, a biasing spring 602 may be provided to automatically returnthe piston 416 and ram 344 into the floor cleaning or storage position.The biasing spring 602 may be disposed between a flange 417 locatedalong the piston rod 416 b and a wall segment 604 located inside therobot housing 140. The biasing spring 602 can be biased into theexpanded position. Accordingly, in the docked position (FIG. 14A) thebiasing spring 602 may be compressed, and upon un-docking the robotvacuum 104, the biasing spring 602 may automatically expand to drive thepiston 416 back into the storage or floor cleaning position.

It will be appreciated that the piston may be actuated by an activationswitch 288 and the movement of piston 416 may be driven by an electricmotor.

Referring now to FIGS. 15-16, which exemplify embodiments of amechanical dirt transfer mechanism that is located inside of the dockingstation 108, rather than the robotic vacuum cleaner 104. The mechanicaldirt transfer mechanism exemplified in FIGS. 15-16 can be used alone, orin conjunction with the any of the dirt transfer mechanisms, previouslyexemplified in FIGS. 10-14. According to such an embodiment, amechanical transfer member 344 is extended from the docking stationthrough the inlet of the docking station 108 and the dirt outlet 168 ofthe robot 104 into the robot dirt bin 176, optionally to the rear end176 b of the robot dirt bin. The member may then be reconfigured to pullor draw dirt from the robot dirt bin 176 into the docking station 108.In accordance with such an embodiment, the member 344 that is insertedinto the robot dirt bin 176 may be configured (during the insertionstage of a cleaning cycle), to pass, e.g., through or above the dirt inthe robot dirt bin 176. Upon completion of the insertion stage, theinward end of the member may be reconfigured so as to engage of pulldirt out of the robot dirt bin 176 during the retraction stage of thecleaning cycle.

As best exemplified in FIG. 15A, docking station 108 may include twocompartments, a first compartment 108 a for containing the dirtreceptacle 248, and a second compartment 108 b for housing themechanical dirt transfer mechanism 344. In the exemplified embodiment,the second compartment 108 b is arranged rearward, and in parallel tothe first compartment 108 a (i.e., on an opposite side of the firstcompartment 108 a from the docking station opening 262 a).

As exemplified, an inter-compartment opening 262 b is disposed betweenthe first and second compartments 108 a, 108 b, and is provided to allowthe dirt transfer mechanism to extend into and through the dirtreceptacle 248. Optionally, an openable door 272 ₂ covers the secondaryopening 262 b, and is pivotally connected inside the docking housing 110by a hinge 274 b.

As further exemplified, the dirt receptacle 248 can also include asecondary opening 252 b, which aligns with the inter-compartment opening262 b. As exemplified, secondary opening 252 b is located on an oppositelateral face of the dirt receptacle 248 from the opening 252 a, whichaligns with the primary docking station opening 262 a. Similar to theprimary opening 252 a, a flap (or door) 254 b may cover, or seal,secondary opening 252 b. In some cases, openable door 272 ₂ ofinter-compartment opening 262 b may not be provided, and only thereceptacle flap (or door) 254 b included.

Similar to the embodiments previously exemplified in FIGS. 10-14, thedirt transfer mechanism 344 in FIG. 15 can comprise a “ram”-likemechanism 344. As best exemplified in FIG. 15A, ram 344 includes a drivemember 344 b (e.g., ram stem 344 b) which extends between a first openend 344 b ₁ and a second open end 344 b ₂. In the exemplifiedembodiment, the ram stem 344 b is formed from a flexible hollow member.

Ram 344 is driven between a storage position (FIG. 15A) and one or moredirt emptying positions (FIGS. 15B-15D) using rotating gears 348 a, 348b. Similar to the gear 348 exemplified in FIG. 11, each gear 348 a, 348b is driven by respective motors 352, via a motor shaft 352 a (notillustrated). Further, each motor 352, controlling each gear 348, may inturn be controlled by a respective control unit 350 a, 350 b. While twogears 348 are exemplified in FIG. 15, it will be understood that anynumber of gears can be provided to translate the ram 344.

In the storage position (FIG. 15A), a portion of stem 344 b may beoriented generally vertically (i.e., transverse to axis 138), such thatthe first end 344 b ₁ is positioned above the second end 344 b ₂. Anadvantage of this configuration is that the ram 344 can be stored in avertically-configured compartment 108 b, which can help reduce the depthof the docking station 108, and minimize its occupied storage space. Inother cases, ram 344 b can be configured to be stored horizontally(e.g., along axis 138 or transversely). Alternately, or in addition, itwill be appreciated that the ram stem 344 b may be a telescoping member.

As further exemplified, ram stem 344 b is axially lined with grooves346, which engage gears 348 a, 348 b, respectively. As exemplified,gears 348 are positioned on opposite longitudinal edges of ram stem 344b. The engagement of grooves 346 with gears 348 allows gears 348 totranslate the stem 344 b between the storage and one or more dirtemptying positions.

As best exemplified in FIG. 15A, a cable 444 extends inside, and throughthe hollow interior of stem 344 b, between a first cable end 444 a and asecond cable end 444 b (e.g., like a Bowden cable). The first cable end444 a is wound around a spool 450, which is in turn, rotated by a spoolmotor 448. Spool motor 448 is used to wind or unwind the spool 450, andis controlled by control unit 350 c, via wire 365 c. In the exemplifiedembodiment, control unit 350 c is connected, e.g., via wire 472, tocontrol units 350 a, 350 b in order to synchronize spool motor 448 withgear motors 352. As further exemplified, the second cable end 440 b isconnected to a foldable sweeping portion 344 a of ram 344.

FIGS. 16A-16B exemplify an embodiment of a reconfigurable end of the ramstem 344 b, which as exemplified is a foldable sweeping portion 344 a.The sweeping portion 344 a is reconfigurable between an insertionposition (FIG. 16A) and a sweeping position (FIG. 16B).

As exemplified, foldable sweeping portion 344 a includes a firstsweeping member 344 a ₁ and a second sweeping member 344 a ₂, eachpivotally attached to a holding member 626 by a respective hinge 456 a,456 b. In the insertion position (FIG. 16A), the first sweeping member344 a ₁ is folded to overlie the second sweeping member 344 a ₂.Additionally, in the insertion position, the sweeping portion 344 a maybe nested inside the hollow interior of stem 344 b, proximal the secondend 344 b ₂ of hollow stem 344 b.

In the sweeping position (FIG. 16B), the sweeper 344 a is ejected (e.g.,pushed out) of the hollow stem 344 b by cable 444. This, in turn, allowsthe first sweeping member 344 a ₁ to fold outwardly relative to thesecond sweeping member 344 a ₂. In the exemplified embodiment, thesecond sweeping member 344 a ₂ is positioned below both the firstsweeping member 344 a ₁ and the ram stem 344 b in the folded-outsweeping position.

Optionally, hinges 456 can be configured as a spring hinges that arebiased to the expanded position. In this configuration, hinges 456 canautomatically fold out the sweeper 344 a, when the sweeper 344 a isejected from the hollow stem 344 b.

While the exemplified embodiment illustrates a two-piece sweeper 344 a,it will be appreciated that in other cases, the sweeper 344 a may haveany number of foldable or reconfigurable pieces such that the sweepermay be inserted in an insertion configuration into the robot dirt bin176 and then reconfigured to a sweeping configuration to remove dirtfrom the robot dirt bin 176 as the mechanical transfer member isretracted into the docking station. For example, in some cases, thesweeper 344 may comprise only one of the portions 344 a ₁, 344 a ₂.

As exemplified in FIGS. 15B-15C, during docking of the robotic vacuumcleaner 104, the ram 344 is extended into the dirt emptying position tocommence emptying the robot dirt bin 176. In particular, ram stem 344 bis extended across the first compartment 108 and dirt receptacle 248,and into the robot dirt bin 176. In some cases, ram 344 may only extendpart-way through the first compartment 108 and receptacle 248.

To translate ram 344 into the dirt emptying position, control units 350a, 350 b can activate motors 352 to rotate gears 348 a, 348 b. In somecases, to prevent over extension of ram 344 b, control units 350 a, 350b can control motors 352 to only rotate gears 348 a pre-determinednumber of rotations. Any activation mechanism discussed herein may beused.

As the ram stem 344 b is translated into the dirt emptying position(FIG. 15B), that is optionally proximate the rear end of the robot dirtbin 176, spool motor 448 can unwind cable 444 at the same rate as ramstem 344 b. This allows cable 444 to push forward the sweeping portion344 a at the same rate as ram stem 344 b (FIG. 15B). In the exemplifiedembodiment, control units 350 a, 350 b and 350 c may be coordinated tosynchronize rotation of gear motors 352 and spool motor 448.

As exemplified in FIG. 15C, ram stem 344 b can open docking stationdoors 272 ₁ and 272 ₂, as well as robot bin door 212, as it is beingtranslated into the emptied position.

Once the ram stem 344 b is translated into the dirt emptying position(FIG. 15C), control units 350 a, 350 may stop rotating gear motors 352.Spool motor 448, however, may continuing unwinding cable 444 to ejectthe foldable sweeper 344 a out of the hollow stem 344 b from theinsertion position (FIG. 15B) to the sweeping position (FIG. 15C). Itwill be appreciated that an advantage of folding the sweeper 344 a inthe sweeping position, only once the ram is in the dirt emptyingposition, is to prevent the sweeper 344 a from pushing dirt into therobot dirt bin 176 as the stem 344 b is being translated into the dirtemptying position.

In order to retract the ram 344 back to the storage position (FIGS.15D-15E), control units 350 a, 350 b reverse rotation of gears 348. Gearmotors 352 and spool motor 448 can be synchronized, e.g., via controlunits 350, to ensure cable 444 is retracted at same rate as ram stem 344b. As sweeping portion 344 a is being retracted by cable 444, it may“drag” (e.g., transfer) dirt from the robot dirt bin 176 and into thedirt receptacle 248.

As exemplified in FIG. 15E, prior to returning the ram stem 344 b intostorage compartment 108 b, spooling motor 448 can first wind back cable444. This, in turn, draws the sweeping portion 344 a back into thefolded storage position, inside the hollow stem 344 b. Gear motors 352may then continue rotating gears 348 until the ram stem 344 b isreceived inside the compartment 108 b.

The dirt transfer mechanism exemplified in FIG. 15 can be activated inany suitable manner and may use any activation switch discussed herein.In the exemplified embodiment, the control units 350 are automaticallyelectrically activated upon docking the robot 104. For instance, asexemplified in FIG. 15A, control units 350 are connected, e.g., via wire364, to activation unit 360. Activation unit 360 is located at the frontend 124 of docking housing 110. Upon docking robot 104, the activationunit 360 is activated, and transmits an activation signal to controlunits 350. This, in turn, causes the control units 350 to activate gearmotors 352 and spool motor 448.

(b) Pneumatic Dirt Transfer Mechanism

Alternately, or in addition to mechanically transferring dirt from therobot dirt bin to the dirt receptacle 248, pneumatic transfer may beprovided. Accordingly, a suction and/or blowing device may be positionedin any one or more of the robotic vacuum cleaner 104 (FIGS. 17-20),docking station 108 (FIGS. 21-24) and/or at a connection interface 264provided between the docking station 108 and a docked robotic vacuumcleaner 104 (FIGS. 25-29).

For example, air may be blown through part or all of the robot dirt binto move or assist in moving dirt into the docking station. The suctionmotor to direct air through the robot dirt bin may be provided at anylocation, such as in the docking station, a connection interface 264 orthe robotic surface cleaning apparatus. The suction motor 180 of therobotic vacuum cleaner that is used in a cleaning operation may be usedfor such pneumatic transport. Alternately, a secondary suction motor maybe provided inside the robotic vacuum cleaner, which may operate toprovide a slower air flow rate than the suction motor 180, may be usedto provide such pneumatic transport during an emptying cycle.

Alternately, air may be drawn out of the robot dirt bin. The suctionmotor 180 of the robotic vacuum cleaner that is used in a cleaningoperation may be used for such pneumatic transport. Alternately, asecondary suction motor may be provided inside the robotic vacuumcleaner, which may operate to provide a slower air flow rate than thesuction motor 180, may be used to provide pneumatic transport during anemptying cycle. An advantage of such a design is that the dockingstation need not have a separate suction motor, which may simplify theconstruction of the docking station. In accordance with such a design,the suction motor of the robot vacuum cleaner, whether the primarysuction motor 180 and/or a secondary suction motor, may be operable toblow air through part or all of the robot dirt bin 176 during anemptying cycle.

As exemplified in FIGS. 17-20, the suction motor used for such pneumaticdirt transport may be located inside of the robotic vacuum cleaner 104.

FIG. 17 exemplifies a first embodiment for a pneumatic dirt transfermechanism that is located inside of the robotic vacuum cleaner 104 andthat uses the suction motor 180 of the robotic vacuum cleaner 104 in adirt emptying mode. In accordance with such an embodiment, one or morevalves may be used to reconfigure the air flow induced by the suctionmotor 180 through the robotic vacuum cleaner 140 between a primary floorcleaning air flow path (used during a floor cleaning mode of operation)and a secondary dirt emptying air flow path (used in a dirt emptyingmode).

In the exemplified embodiment, suction motor 180 is connectable in fluidflow communication with a primary or cleaning airflow path 184 a (FIG.17A), and a secondary or dirt emptying airflow path 184 b (FIG. 17B).

As exemplified in FIG. 17A, the primary flow path 184 a may be usedduring normal cleaning operation when the robotic vacuum cleaner 104 isoperating in a floor cleaning mode. The primary flow path 184 a and canextend between a dirty air inlet 172 (as exemplified in FIG. 3) and theclean air outlet 196. During the floor cleaning mode, air is drawnthrough the dirty air inlet 172 via the primary path 184 a to the robotdirt bin 176, via dirt inlet 188, and then out the robot dirt bin 176through a first air passage 192 a via air outlet 206, and then continuesdownstream to an inlet of suction motor 180. Air is then ejected fromthe suction motor 180 to the clean air outlet 196, via a second airpassage 192 b.

As exemplified in FIG. 17B, to transfer dirt and debris from dirt bin176, air exiting suction motor 180, the robotic vacuum cleaner 104 maybe operated in a dirt emptying mode whereby air flow may be re-directedback into the robot dirt bin 176 along the secondary airflow path 184 b.Second air flow path 184 b comprises a third air passage 192 c, whichconnects the suction motor 180 outlet to an air inlet 484 of the robotdirt bin 176 (also referred to herein as dirt collection region airinlet port 484). The end of the passage 192 c located at the downstreamside of the suction motor 180 may be regarded as an inlet end of thesecondary air flow path 184 b (e.g., a secondary air flow path airinlet). Preferably, as exemplified, air inlet 484 is positioned at arear-end 176 b of the dirt bin 176. In this configuration, air exitinginlet 484 can blow dirt and debris toward the front-end of the dirt bin176, and into the docking station 108. A filter medium 488 and/or anopenable door may cover the air inlet 484 to prevent a backflow of dirtfrom entering air passage 192 c, during normal cleaning operation.

As exemplified, two valves (a first valve 478 a and a second valve 478b) are provided to re-direct airflow between the primary and secondaryairflow paths. As exemplified, the first valve 478 a may be located inthe second air passage 192 b, while the second valve 478 b may belocated in the third airflow passage 192 c.

As exemplified in FIG. 17A, during the floor cleaning mode of operation,the first valve 478 a is opened while the second valve 478 b is closed.This configuration blocks airflow from entering air passage 192 c (i.e.,into dirt bin 176), and directs air toward the clean air outlet 196(i.e., along the primary airflow path 184 a).

As exemplified in FIG. 17B, when it is desired to empty the dirt bin 176to operate the robot vacuum 104 in a dirty emptying mode, the valveconfiguration is reversed, such that the first valve 478 a is closed,and the second valve 478 b is opened. In this manner, airflow isre-directed, through air passage 192 c, into the dirt bin air inlet 484(i.e., along the secondary airflow path 184 b). Accordingly, the valves478 can be used to selectively connect the secondary air flow path 184 bin fluid flow communication with the suction motor 180. As exemplified,as air is directed into the robot dirt bin 176, it may push dirtcollected inside the robot dirt bin 176 forwardly through the robot dirtoutlet 168, and into the docking station 108. Optionally, asexemplified, the docking station 108 may include a clean air outlet 608.Air flow into the docking station may exit through the clean air outlet608, via an opening 612, and into the ambient surrounding. A filtermedia 608 may be located to prevent dirt plumes from forming as a resultof air-entrained dirt being carried through the outlet 610. While theillustrated embodiment shows the clean air outlet 608 as being locatedat an upper end 116 of the docking station 108, in other embodiments,the clean air outlet 608 may be located at any other suitable location.

While the exemplified embodiment illustrates two valves, it will beappreciated that any number of valves can be provided. For example, asingle three-way valve can be used to re-direct air between the cleanair outlet 196 and the robot dirt bin 176.

FIGS. 17C and 17D exemplify an embodiment of the valve 478. In theexemplified embodiment, each valve 478 comprises a butterfly valve. Inthe open position (FIG. 17C), the valve 478 is rotated in an axisgenerally parallel to an axis 193 of passage 192. In this position,airflow passes through air passage 192. As exemplified in FIG. 17D, thevalve 478 can be closed by rotating the valve such that it is generallytransverse with the passage axis 193. In this orientation, airflow isblocked from passing through the passage 192.

It will be appreciated that while the exemplified embodiment illustratesbutterfly valves, any other suitable valves known in the art may also beused. For instance, valves 478 can comprise ball valves, gate valves orcheck valves, or otherwise, any switch mechanism capable of divertingand re-directing airflow.

In the exemplified embodiment, motors 352 ₁, 352 ₂ are provided torotate valves 478 a, 478 b, respectively, between the open and closedpositions. As illustrated in FIGS. 17C and 17D, valves 478 a, 478 b aremounted to drive shafts 352 a ₁, 352 a ₂ of motors 352 ₁, 352 ₂,respectively, allowing motors 352 to rotate the valves 478.

Motors 352 may be activated in any suitable manner to re-configure thevalves 478 between the open and closed positions. For instance, asexplained previously with respect to FIGS. 10-16, an activation unit 360can be provided to activate motors 352, via control unit 350. Anyactivation mechanism discussed herein may be used. For example,activation unit 360 may be automatically activated upon docking robot104, or otherwise.

While the embodiment of FIGS. 17A and 17B exemplify the first airflowconduit 192 a being the source of air used in the dirt emptying mode, itwill be appreciated that the source of air may be located elsewhere,such as a location downstream from dirt outlet port 168 during theemptying mode (e.g., in an interface 264 as exemplified in FIG. 19A orin the docking station or on an outer surface of the robotic surfacecleaning apparatus). In such a case, a further vale may be used toconnect the suction motor 180 inlet end to such a source of air.

FIGS. 18A-18B exemplify an alternative embodiment of a pneumatic dirttransfer mechanism that also uses the suction motor 180 of the roboticvacuum cleaner 104. In contrast to the configuration of FIGS. 17A-17B,the secondary flow path 184 b in FIG. 17 extends between an upstreamside of the suction motor 180, and an air inlet 484 of the robot dirtbin 176. In the floor cleaning mode (FIG. 18A), the valve switch 478 ais opened, while the valve switch 478 b is closed and the suction motor180 may drive an internal fan blade in a first direction to drive theflow of air along the primary air flow path 184 a. That is, the flow ofair is driven from the robot dirty air inlet 172, through the robot dirtbin 176 and to the clean air outlet 196. In the dirt emptying mode (FIG.18B), the valve switch 478 a is closed, while the valve switch 478 b isopened. The direction of rotation of the internal fan blade of suctionmotor 180 is then reversed such that the suction motor 180 inlet is nowan air outlet. In this configuration, the flow of air is driven from theair inlet 196, through the air passage 192 c and into the robot dirt bin176 via the air inlet 484. The air being blown into the robot dirt bin176 from air inlet 484 may push collected debris out of the robot vacuumcleaner via dirt outlet 168. Optionally, as exemplified, operation ofthe suction motor 180 between the floor cleaning and dirty emptying modecan be controlled by the activation unit 350, via a connecting wire 628.It will be appreciated that this embodiment may utilize any motor andfan blade assembly that, in a first mode of operation, directs air in afirst direction and, in a second mode of operation, directs air inanother (e.g., the opposite) direction. It will also be appreciated thatwhile this embodiment exemplifies the use of air outlet 196 as thesource of air in the dirt emptying mode, the source or air may be analternate inlet port. In such a case, a further vale may be used toconnect the suction motor 180 to such a source of air.

FIGS. 19A-19C exemplify still an alternative embodiment of a pneumaticdirt transfer mechanism that also uses the suction motor 180 of therobotic vacuum cleaner 104. The exemplified embodiment of FIG. 19 alsooperates generally analogous to the embodiment exemplified in FIG. 17,with the exception that re-directed airflow is entering the suctionmotor 180, rather than exiting the suction motor 180. According to suchan embodiment, air is drawn by suction motor 180 out of the dirt outletport 168 of the robot dirt bin 176.

In the exemplified embodiment, the third airflow conduit 192 c extendsbetween a first end 192 c ₁ and a second end 192 c ₂. The first end 192c ₁ connects to the first airflow conduit 192 a, which directs air intothe suction motor 180 inlet. The second end 192 c ₂ is an open endprovided at, e.g., a front end 156 of the robotic vacuum cleaner 104.

As further exemplified in FIG. 19B, the docking station 108 alsoincludes an air passage 520. Air passage 520 comprises an air outlet end520 a, disposed at a front end 124 of the docking station housing 110,along the upright section 112, and an air inlet end 520 b, provided atthe docking station opening 262. It will be appreciated that inlet end520 b may be located anywhere on interface 264 or the docking station.

In the exemplified embodiment, the first valve 478 a is located insidethe first air passage 192 a, while the second valve 478 b is locatedinside the third air passage 192 c.

As exemplified, during the floor cleaning mode of operation (FIG. 19A),the first valve 478 a is open, and the second valve 478 b is closed. Inthis configuration, airflow travels along the primary airflow path 184a, from the robot dirty air inlet 172, through the robot dirt bin 176 tothe suction motor 180 inlet, and out of the clean air outlet 196.

Upon docking the robotic vacuum cleaner 104, the vacuum cleaner 104 isoperated in a dirty emptying mode whereby the second open end 192 c ₂ ofair passage 192 c, engages (e.g., abuts) the outlet end 520 a of dockingstation passage 520 (FIG. 19B). The first valve 478 a is then closed,and the second valve 478 b is opened.

In this configuration, air is drawn by suction motor 180 through airinlet 520 b, and flows along a secondary airflow path 184 b comprisingthe docking station air passage 520 and the third air passage 192 c, andtoward the suction motor 180. In the exemplified embodiment, thesuctioning of air through inlet 520 b, draws dirt and debris out of therobot dirt bin 176, and into the docking station 108. Preferably, asexemplified, docking station air inlet 520 b is directed to face therobotic vacuum cleaner 104, in order to draw air from the dirt bin 176.

Preferably, as exemplified, the configuration in FIG. 19B is used inconjunction with a secondary (e.g., mechanical) dirt transfer mechanism,such as a mechanical ram 344 provided inside of the robot 104. In thisconfiguration, the ram 344 can be used to push dirt and debris towardthe front end of dirt bin 176, and the suction at inlet 520 b canfurther facilitate drawing the dirt inside the docking station 108.

It will be appreciated that in the dirt emptying mode of operation, thesuction motor 180 may operate at a slower speed so as to limit the dirtwhich is entrained in an air stream and drawn into air passage 192 c.

As exemplified, sealing members 197 a, 197 b can be provided around thesecond end 192 c ₂ of air passage 192 c, and the outlet end 520 a ofdocking station air passage 520, respectively. The sealing members 197can comprise a gasket or the like, and can prevent air leakage betweenair passage 192 c and air passage 520 during an emptying cycle. Asfurther exemplified, a filter medium 527 may optionally cover thedocking station air inlet 520 b to prevent dirt and debris from enteringthe air passage 520.

Optionally, as exemplified in FIGS. 19B and 19C, bellows 106—is disposedbetween the docking station 108 inlet 262 and the robotic vacuum cleaner104 dirt outlet port 168 which—may include one or more openings orperforations 540 extending therethrough. As exemplified in FIG. 19B, asair is being drawn through air inlet 520 b, the reduced pressure in thedirt transfer passage (the passage between outlet port 168 of roboticvacuum cleaner 104 and opening port 262 of the docking station 108) candraw ambient air through the gasket perforations 540. An advantage ofthis configuration is that dust or dirt, which may escape during anemptying cycle of the robot dirt bin 176, can be drawn back through thegasket perforations 540. In particular, this can prevent formation ofdust plumes around the combined apparatus 100. In other embodiments,rather than providing a bellows 106, any other sealing member (e.g., agasket) having one or more openings can be provided.

As exemplified in FIGS. 20A and 20B, the pneumatic dirt transfermechanism may use a second suction motor located inside the roboticvacuum cleaner 104, which differs to the suction motor 180 of roboticvacuum cleaner 104 that is used during the floor cleaning mode ofoperation. Accordingly, the robotic vacuum cleaner 104 may comprise asuction motor 180 for use in a floor cleaning mode and a suction motorfor use in a dirt emptying mode. In the exemplified embodiments, thesuction motor for use in the dirt emptying mode can be located eitheroutside of the robot dirt bin 176 (FIG. 20A), or inside of the robotdirt bin 176 (FIG. 20B).

As exemplified in FIG. 20A, suction motor 504 is positioned rearward ofthe dirt bin 176, and within a secondary airflow path 184 b. Thesecondary airflow path 184 b extends between an inlet end 196 c ₁ of airpassage 192 c, located on the exterior of robot body 140, and air inlet484 of robot dirt bin 176.

Upon activating suction motor 504, ambient air is drawn through the airinlet 196 c ₁ and into air passage 196 c. The air may then flowdownstream, through the conduit 196 c, to a second end 196 c ₂ of theair passage, positioned at the suction motor 504 inlet. Suction motor504 then ejects the suctioned air into the dirt bin 176, via the dirtbin inlet 484, so as to blow (e.g., eject) dirt and debris out of thebin 176, and into the docking station 108 via the dirt outlet port 168of the robotic vacuum cleaner 104.

In the exemplified embodiment, a filter media 486 can cover the airinlet 192 c ₁ to prevent dirt and debris from being suctioned into airpassage 192 c from the ambient surrounding. Preferably, as exemplified,air inlet 484 is also positioned at a rear end 176 b of the bin 176, soas to blow dirt forwardly, toward an opened front end 176 a of bin 176.

FIG. 20B exemplifies a similar configuration to FIG. 20A, with theexception that the suction motor 504 is now positioned inside the robotdirt bin 176, and forward of the dirt bin air inlet 484.

In the exemplified configuration, the dirt bin air inlet 484 iscontiguous with the second end 192 c ₂ of the air passage 192 c. Suctionmotor 504 draws air through the inlet 484, and directs the air directlyinto the dirt bin 176. Optionally, as exemplified, the filter medium 488can be positioned forward of the suction motor 504, to prevent dirt anddebris from clogging the suction motor 504 fan during normal cleaningoperation.

In the configurations exemplified in FIGS. 20A and 20B, the suctionmotor 504 can be activated in any suitable manner and may use anyactivation mechanism discussed herein. For instance, as exemplified,suction motor 504 can be controlled by a control unit 350 (e.g., viawire 365), which is in turn, connected to an activation unit 360 (e.g.,via wire 364). Activation unit 360 can function as previouslyexemplified with respect to FIGS. 10-12. In various cases, uponreceiving an activation signal from activation unit 360 (i.e., atdocking), control unit 350 can activate suction motor 504 for all or aportion of the time during which robotic vacuum cleaner 104 is docked.In other cases, control unit 350 can activate suction motor 504 for onlya pre-determined interval of time before de-activating the suctionmotor. In some cases, suction motor 180 can be turned off prior toactivating suction motor 504 (i.e., using power switch 164 in FIG. 2).

It will be appreciated that, in any embodiment wherein air is blownthrough the robot dirt bin, the air inlet and air outlet may be locatedat any location. Optionally, as exemplified, the air is directedlinearly through the robot dirt bin. Accordingly, the air inlet and theair outlet may be spaced apart and face each other. For example, asexemplified in FIGS. 17A, 17B, 18A, 18B, 20A and 20B, optionally, theair inlet and the air outlet in the dirt emptying mode are on opposedsidewalls such that air is blown over the floor of the robot dirt binfrom one end to the other.

Referring now to FIGS. 21-24, which exemplify various embodiments for asuction motor 504 positioned inside the docking station 108, rather thanrobotic vacuum cleaner 104. It will be appreciated that the exemplifiedembodiments can be used separately, or in conjunction with any of theembodiments previously exemplified in FIGS. 17-20.

FIGS. 21A-21B exemplify a first embodiment for a suction motor 504located inside the docking station 108. As best exemplified in FIG. 21B,docking station 108 includes the suction motor 504, positioned between afirst air passage 520 and a second air passage 522.

First passage 520 extends between an inlet end 520 a and an outlet end520 b. As exemplified, the inlet end 520 a is downward facing and isconfigured to overlie the robotic vacuum cleaner 104 during docking,while outlet end 520 b feeds into the suction motor 504. The secondpassage 522 also includes an inlet end 522 a, located at the suctionmotor 504 outlet, and an outlet end 522 b, located at the dockingstation opening 262. In the exemplified embodiment, the outlet end 522 bfaces into the docking station 108.

As further exemplified in FIG. 21A, robotic vacuum cleaner 104 includesan air passage 192 c. Air passage 192 c includes an inlet end 192 c ₁,positioned proximal the robotic vacuum cleaner outlet port 168, andfacing toward dirt bin 176. An outlet end 192 c ₂ of the air passage isprovided at an upper end 144 of robot housing 140.

In the exemplified embodiment, when in the docking position (FIG. 21B),outlet end 192 c ₂ of robotic vacuum cleaner 104 aligns with downwardfacing inlet end 520 a of the docking station 108. Optionally, sealingmembers 197 a, 197 b are provided at the outlet end 192 c ₂ and inletend 520 a, respectively.

Upon activating suction motor 504 (e.g., using activation unit 360)(FIG. 21B), air is drawn from the robot dirt bin 176, via the air inlet192 c ₁, and through passages 192 c and 520. The suction force at theair inlet 192 c ₁ draws dirt and debris out of the dirt bin 176, anddirects it towards the robot outlet port 168. As exemplified, air drawnby suction motor 504 is then drawn into the docking station opening 262via the air outlet 522 b. The air blown out of outlet 522 b facilitatespushing the dirt and debris that has been drawn from robot dirt bin 176into the dirt receptacle 248.

Such an embodiment may be used in conjunction with a mechanical dirttransfer system. The suction motor 504 may operate at a relatively lowlevel of suction so as to assist with the dirt transfer.

FIGS. 22A-22B exemplify an alternative configuration for a suction motor504 located inside of the docking station 108 wherein suction motor 504is used to blow air through the robot dirt chamber. The exemplifiedarrangement is generally analogous to FIGS. 21A-21B, with the exceptionthat: (i) suction motor 504 is inverted to draw air through inlet 522 b,and eject air through outlet 520 a; (ii) air inlet 522 b is directedtoward the docked robotic vacuum cleaner 104 and (iii) air outlet 520 ais located at a front end 124 of docking station 108, along uprightsection 112, and faces forwardly.

Further, in the exemplified embodiment, the first open end 192 c ₁ ofair passage 192 c, which is inside the robotic vacuum cleaner 104, islocated at the front end 156 of the vacuum body 140, while the secondopen end 192 c ₂ is positioned at the air inlet 484 of robot dirt bin176.

Upon docking the vacuum cleaner 104 (FIG. 22B), the open end 192 c ₁ ofair passage 192 c, aligns with the outlet end 520 a of the dockingstation 108. The activated suction motor 504 draws air through inlet 522b and passage 522, and ejects the air through passages 520 and 192 c,and into the robot dirt bin 176 via air inlet 484. Accordingly, airexiting the dirt bin inlet 484 can push dirt, forwardly, out of the dirtbin 176, and toward the docking station 108. The complementary suctionforce at inlet 522 b may further assist in drawing dirt and debris intothe docking station 108.

Optionally, as exemplified, a sealing member 106, having one or moreperforations 540, can be provided between the docking station 108 andthe robotic vacuum cleaner 104.

FIG. 23 exemplifies still a further alternative configuration for asuction motor 504 located inside of the docking station 108. Theexemplified configuration of FIG. 23 is generally analogous to theconfiguration previously exemplified in FIG. 22, with the exception thatthe suction motor 504 ejects air, from outlet 522 a, directly into theambient surrounding. Accordingly, in this configuration, an airflowpassage 192 c is not required inside of the robotic vacuum cleaner 104.

Preferably, in the exemplified configuration, a secondary (e.g.,mechanical) dirt transfer mechanism (e.g., ram 344 inside robot 104) isprovided to facilitate pushing of dirt and debris toward the suctionpoint 522 b, and further into the dirt receptacle 248.

FIGS. 24A-24B exemplify still a further alternative configuration for asuction motor 504 inside of the docking station 108. In this embodiment,the suction motor 504 configuration exemplified in FIGS. 24A-24B isanalogous to the configuration previously exemplified in FIG. 23, withthe exception that the suction motor 504 is: (i) inverted to suctionambient air through an inlet 520 a, and eject air through an outlet 522b; and (ii) the air outlet 522 b is directed into the docking station108, so as to blow dirt and debris toward the dirt receptacle 248. Inthe exemplified embodiment, air inlet 520 a is provided at the front end124 of docking station 108, along the upright section 112.

An advantage of the exemplified configuration is that the suction motor504 can be used to draw air-borne containments, which escape whenemptying robot bin 176 into docking station 108.

In particular, as exemplified, suction point 520 a can include a filtermedia 527 a, which can be used to capture air-borne contaminants whichescape while emptying the robot dirt bin 176. Once the suction motor 504is de-activated, dirt collected on filter media 527 a may, for example,collapse on the surface located around the docking station 108. Thecollapsed dirt may then be swept and cleaned by a user. As exemplifiedin FIG. 24B, the suction motor 504 can also be used to prevent dustplumes from forming while undocking robot 104. For instance, suctionmotor 504 can be activated while un-docking the robot to prevent debristhat was not fully transferred, between the dirt bin 176 and dockingstation 108 during cleaning from becoming air borne. It will beappreciated that the use of a suction motor to reduce or prevent dustplumes for forming upon de-docking may be used in any embodimentdisclosed herein.

Optionally, as previously discussed and as exemplified, a secondary(e.g., mechanical) dirt transfer mechanism (e.g., ram 344 inside roboticvacuum cleaner 104) can be provided to facilitate pushing of dirt anddebris out of the robot dirt bin 176 and toward the docking station 108.For example, ram 344 may push dirt toward the docking station opening262, and air being blown out of outlet 522 b can further push theejected dirt and debris into the dirt receptacle 248.

Alternately, as discussed previously, an interface may be providedbetween the robotic vacuum cleaner 104 and the docking station 180. Theinterface may be part of the docking station and may be removablymounted thereto or non-removably mounted thereto. FIGS. 25-29 exemplifyvarious embodiments for a suction motor 504 provided in connectioninterface 264. The exemplified embodiments can be used separately, or inconjunction with the embodiments previously exemplified in FIG. 17-23.

As best exemplified in FIG. 24, the connection interface 264 cancomprise a housing portion 264 a for housing suction motor 504, and apassage portion 254 a which extends between a first open end 264 b ₁ anda second open end 264 b ₂. As exemplified, the first open end 264 b ₁aligns with the robotic vacuum cleaner outlet 168 when the roboticvacuum cleaner is docked, while the second open end 264 b ₂ aligns withthe docking station opening 262.

In the exemplified embodiment, the housing portion 264 a is positionedabove the passage portion 264 b. However, it will be appreciated that inother embodiments, the housing portion 264 a can be positioned at anyother location relative to passage portion 264 b. For example, housingportion 264 a can be disposed lateral to, or below passage portion 264b.

FIG. 25 exemplifies a first embodiment of a suction motor 504 positionedinside the connection interface 264. As exemplified, the suction motor504 draws (e.g., suctions) ambient air, through the air inlet 520 a. Airflows to suction motor 504 via passage 520. Suction motor 504 ejects theair through airflow passage 522, and into passage portion 264 b ofconnection interface 264 (e.g., via outlet 522 b). In the exemplifiedconfiguration, outlet 522 b is oriented toward the docking station 108,and further is positioned proximal the first open end 264 b ₁ of passage264 b. In this configuration, air ejected from outlet 522 b can be usedto blow dirt and debris from the robot dirt bin 176 into the dockingstation 108.

Preferably, as exemplified, the configuration exemplified in FIG. 25, isused in conjunction with a secondary (e.g., mechanical) dirt transfermechanism. For example, as exemplified, ram 344 inside robotic vacuumcleaner 104 can be used to eject dirt out of the robot dirt bin 176, andinto the connection interface 264. Air ejected from suction motor 504 isthen used to blow ejected dirt, further into the docking station 108.

FIGS. 26-28 exemplify still further embodiments of a suction motor 504positioned inside the connection interface 264. The embodimentexemplified in FIGS. 26-28 are generally analogous to the exemplifiedembodiment of FIG. 25, with the exception that: (i) the configuration ofsuction motor 504 is reversed to suction air from inlet 522 b, and ejectair through outlet 520 a; (ii) the air inlet 522 b is directed to facethe docked robotic vacuum cleaner 104 in order to suction air from therobot dirt bin 176.

Optionally, a sealing member 106 having one or more perforations 540 canbe provided between the connection interface 264 and the robotic vacuumcleaner 104.

In the exemplified embodiment, the air outlet 520 a can be positioned toeject air into the ambient surrounding (FIG. 26), into the dockingstation 108 (FIG. 27), into the passage portion 264 b (FIG. 28), or intoan air passage 192 c located inside of the robotic vacuum cleaner 104,which further directs air into the dirt bin 176, via air inlet 484 (FIG.29). In particular, the embodiment exemplified in FIG. 28 may operategenerally analogously to the embodiment previously exemplified in FIG.21, with the exception that the suction motor 504 is provided inside theconnection interface 264, rather than docking station 108.

It will be appreciated that a mechanical dirt transfer mechanism may beused in conjunction with any pneumatic dirt transfer mechanism.

While the above description describes features of example embodiments,it will be appreciated that some features and/or functions of thedescribed embodiments are susceptible to modification without departingfrom the spirit and principles of operation of the describedembodiments. For example, the various characteristics which aredescribed by means of the represented embodiments or examples may beselectively combined with each other. Accordingly, what has beendescribed above is intended to be illustrative of the claimed conceptand non-limiting. It will be understood by persons skilled in the artthat other variants and modifications may be made without departing fromthe scope of the invention as defined in the claims appended hereto. Thescope of the claims should not be limited by the preferred embodimentsand examples, but should be given the broadest interpretation consistentwith the description as a whole.

1. An apparatus comprising a docking station and an autonomous surfacecleaning apparatus wherein, the autonomous surface cleaning apparatuscomprises: (a) a primary air flow path extending from a dirty air inletto a clean air outlet: (b) a primary suction motor positioned in theprimary air flow path; and (c) an air treatment unit positioned in theprimary air flow path, the air treatment unit comprising a dirtcollection region; and wherein the docking station comprises a dirtreceptacle and a mechanical dirt transfer mechanism operable to transferdirt that has collected in the dirt collection region from the dirtcollection region to the dirt receptacle.
 2. The apparatus of claim 1wherein, when the autonomous surface cleaning apparatus is positioned ona floor, the air treatment unit has an upper side, a lower side, a firstend having a first side positioned between the upper and lower sides anda second end having a second side positioned between the upper and lowersides, the second side is spaced apart from the first side in a firstdirection and, the mechanical transfer member is moveable in the firstdirection through at least a portion of the air treatment unit wherebydirt collected in the air treatment unit is moved in the first directionthrough the air treatment unit.
 3. The apparatus of claim 1 wherein,when the autonomous surface cleaning apparatus is positioned on a floor,the air treatment unit has an upper side, a lower side, a first endhaving a first side positioned between the upper and lower sides and asecond end having a second side positioned between the upper and lowersides, the second side is spaced apart from the first side in a firstdirection, the second side has a dirt outlet and, in a dirt emptyingmode, the mechanical transfer member is moveable through the dirt outlettowards the first side and then moveable in the first direction backthrough the dirt outlet.
 4. The apparatus of claim 3 wherein themechanical transfer member comprises a sweeping portion and a driveportion, the sweeping portion is reconfigurable between in insertionposition in which the sweeping portion is positioned above the lowerside and a sweeping position in which the sweeping portion extendsdownwardly from the drive portion.
 5. The apparatus of claim 1 whereinthe autonomous surface cleaning apparatus has a robot bin door whichcloses the dirt outlet and the mechanical dirt transfer mechanism opensthe robot bin door when the mechanical dirt transfer mechanism isactuated.
 6. The apparatus of claim 1 wherein the docking station has anopenable door which closes a dirt inlet of the dirt receptacle and themechanical dirt transfer mechanism opens the openable door when themechanical dirt transfer mechanism is actuated.
 7. The apparatus ofclaim 6 wherein the autonomous surface cleaning apparatus has a robotbin door which closes the dirt outlet and the mechanical dirt transfermechanism opens the robot bin door when the mechanical dirt transfermechanism is actuated.
 8. The apparatus of claim 1 wherein theautonomous surface cleaning apparatus has a robot bin door which closesthe dirt outlet and the robot bin door is opened when the autonomoussurface cleaning apparatus docks at the docking station.
 9. Theapparatus of claim 1 wherein the docking station has an openable doorwhich closes a dirt inlet of the dirt receptacle and the openable dooris opened when the autonomous surface cleaning apparatus docks at thedocking station.
 10. The apparatus of claim 9 wherein the autonomoussurface cleaning apparatus has a robot bin door which closes the dirtoutlet and the robot bin door is opened when the autonomous surfacecleaning apparatus docks at the docking station.
 11. The apparatus ofclaim 1 wherein the autonomous surface cleaning apparatus has a robotbin door which closes the dirt outlet and the robot bin door is openedwhen an emptying mode of the autonomous surface cleaning apparatus isactuated.
 12. The apparatus of claim 1 wherein the docking station hasan openable door which closes a dirt inlet of the dirt receptacle andthe openable door is opened when an emptying mode of the autonomoussurface cleaning apparatus is actuated.
 13. The apparatus of claim 12wherein the autonomous surface cleaning apparatus has a robot bin doorwhich closes the dirt outlet and the robot bin door is opened when anemptying mode of the autonomous surface cleaning apparatus is actuated.14. The apparatus of claim 1 further comprising a pneumatic dirttransfer mechanism.
 15. The apparatus of claim 14 wherein the autonomoussurface cleaning apparatus has the pneumatic dirt transfer mechanism.16. The apparatus of claim 1 wherein the mechanical dirt transfermechanism is exterior to the dirt receptacle.